GENERAC 7.5L Diesel Service Manual Reference Mitsubishi 6D16-T 6D162PT 6D162PT041 by engineparts2

Manual Part No. 0E7084

7.5

LITER

MITSUBISHI DIESEL ENGINE

SERVICE MANUAL

GENERAC 7.5 Liter Diesel Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.generac-generator-engine-parts.com

FOREWORD This manual has been published by GENERAC® POWER SYSTEMS, INC. to aid our dealers’ mechanics, company service personnel and general consumers when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured and marketed by GENERAC® POWER SYSTEMS, INC. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required. Proper service and repair is important to the safe, economical and reliable operation of the products described herein. The troubleshooting, testing, service and repair procedures recommended by GENERAC® POWER SYSTEMS, INC. and described in this manual are effective methods of performing such operations. Some of these operations or procedures may require the use of specialized equipment. Such equipment should be used when and as recommended. We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not recommended by the manufacturer must first satisfy himself that neither his safety, nor the product’s safety, will be endangered by the service or operating procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. However, GENERAC® POWER SYSTEMS, INC. reserves the right to change, alter or otherwise improve the product at any time without prior notice. Some components or assemblies of the product described in this manual may not be considered repairable. Disassembly, repair and reassembly of such components may not be included in this manual. The engines described herein may be used to power a wide variety of products. Service and repair instructions relating to any such products are not covered in this manual. For information pertaining to use of these engines with other products, refer to any owner’s or service manuals pertaining to said products.

7.5 Liter Diesel Engine Table of Contents GENERAC SERVICE RECOMMENDATIONS ................................................................................................ A_2 MITSUBISHI FOREWORD AND CONTENTS ........................................................................................................

The 7.5 Liter Diesel Engine has been engineered for use in Generac Power Systems products. The contents of this manual have been reprinted from the original manufacturerâ&#x20AC;&#x2122;s service and repair manual.

7.5 Liter Diesel Engine Service Recommendations

◆ ENGINE OIL RECOMMENDATIONS The unit has been filled with “break in” engine oil at the factory. Use a high-quality detergent oil classified “For Service CC, SD, SE or SF.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change: Engine Lubrication System:

DANGER

! !

Type of Oil Pump ............................................................................Gear Oil Filter ..................................................................Full Flow, Cartridge

Crankcase Oil Capacity ....................................22.7 L (6 U.S. gals.) Temperature Above 86º F (30º C) 32º to 86º F (0º to 30º C) Below 32º F (0º C) All Seasons

Oil Grade (Recommended) SAE 40 or 15W-40 SAE 30 or 15W-40 SAE 20W or 15W-40 SAE 15W-40

◆ COOLANT Use a mixture of half low silicate, ethylene glycol base antifreeze and half soft water. Use only soft water and only low silicate antifreeze. If desired, you may add a high quality rust inhibitor to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture. Cooling System: Type........................................................Pressurized, Closed Recovery

Coolant Capacity System ........................................................17.5 L (4.6 U.S.gals.) Engine..........................................................8.5 L (2.24 U.S.gals.)

Do not remove the radiator pressure cap while the engine is hot or serious burns from boiling liquid or steam could result. Ethylene glycol base antifreeze is poisonous. Do not use your mouth to siphon coolant from the radiator, recovery bottle or any container. Wash your hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them.

Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze, or chromium hydroxide (“green slime”) will form and cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base antifreeze. Using any high silicate antifreeze boosters or additives also will cause overheating. We also recommend that you DO NOT use any soluble oil inhibitor for this equipment.

7.5 Liter Diesel Engine Service Recommendations

PERIODIC MAINTENANCE SCHEDULE:

SERVICE SCHEDULE ◆ AUTHORIZED OPERATOR MAINTENANCE FUNCTIONS Every Month or 100 Hours (whichever comes first)

• • • • • • •

Test standby generator system. Inspect battery and cables. Check engine oil level. Check gearbox oil level (if so equipped). Check engine coolant level. Check generator ground connections. Test/inspect starting aids.

Every Three Months or Every 120 Hours (whichever comes first)

• Inspect and test fuel system and connections. • Inspect exhaust system. • Inspect/test fuel supply system.

◆ AUTHORIZED SERVICE TECHNICIAN MAINTENANCE FUNCTIONS After First 30 Hours of Operation • • • •

Inspect wiring. Change engine crankcase oil and oil filter. Inspect engine fan belts. Inspect battery and cables.

Every Six Months or Every 100 Hours (whichever comes first)

• • • • • • • • • • • • • • •

Change engine oil and filter. Lubricate engine controls. Service engine air cleaner. Service engine fuel filter. Inspect AC generator. Test engine safety controls. Inspect fan belts. Check engine coolant level. Inspect engine cooling system hoses. Check optional starting aids. Check battery. Check engine compression. Check electrical connections. Check/test annunciator panel. Perform operational test.

Annually or Every 600 Hours (whichever comes first)

• • • • • • • •

Check engine valve clearance. Test fuel injection nozzles. Test injection timing. Inspect all wiring. Test engine starter operation. Drain water from fuel tank. Retorque fan bolts. Drain and refill gearbox (if so equipped)

Every Two Years • • • •

Replace all rubber hoses. Replace engine fan belts. Inspect the Standby Generator System. Drain, flush, refill cooling system.

Every 1,000 Operating Hours • • • • •

Inspect engine DC alternator. Inspect engine starter. Retorque engine mounting brackets. Remove/test fuel injection pump. Remove/test cooling system thermostat.

As Required • Bleed engine fuel system.

Notes

601 diesel engine

Shop Manual (for industrial use)

GROUP INDEX HOW TO READ THIS MANUAL

ENGINE . ....................... LUBRICATION .................. FUEL AND ENGINE CONTROL ..

FOREWORD This Shop Manual is published for the information and guid ance of personnel responsible for maintenance of Mitsubishi 6D1 series diesel engine, and includes procedures for ad justment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct service with no wastage. For more details, please consult your nearest authorized Mitsubishi dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future.

-m

GENERAL ......................•

COOLING ...................... INTAKE AND EXHAUST .........

ELECTRICAL SYST EM ..........

Applicable models 6D14 6D14-T 6D15-T 6D16 6D16-E 6D16-T 6D16-PT 6D16-2PT> Generac Engine 0D5703 Reference Mitsubishi 6D16-T 6D162PT 6D162PT041 6D16-TE 6D16-TL 6D16-TLE

Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.generac-generator-engine-parts.com

·lfl ·Dm

-m

·ID ·Ell

I HOW THIS MANUAL IS COMPILED . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL EXPLANATION OF THIS MANUAL . . . . . . . . . . . . . . .

iii

TERMS AND UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

D THIS MANUAL

How This Manual Is Compiled • This manual is compiled by classifying various systems into certain groups. • Each group contains specifications; troubleshooting; maintenance service standards; 0 tightening torque;� lubricant, fluid and sealant;[.&) special tools; and service procedure. • Page enumeration is independent by every group where firs page is always i. Group denomination

Group No. 00

Contents

General

General specifications, engine No. and name plate, precautions for maintenance operations, table of standard tightening torques

Engine

Engine body

Lubrication

Lubrication system

Fuel and engine control

Fuel system

Cooling

Cooling system Intake and exhaust system, turbocharger, intercooler

Intake and exhaust

Clutch

Clutch proper, bearing case

Electrical system

Alternator, starter, preheating system, engine start system, automatic stop system

Special equipment

Air compressor, pressure governor

General Explanation of This Manual • Specifications Particulars relative to maintenance service are made. • Structure and operation (1) Regarding conventional equipment, descriptions are made in brief. (2) Regarding new equipment, descriptions of system and operating condition are made in detail. • Troubleshooting Symptoms of troubles and possible causes are described comparatively. • Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle. • Service procedure In principle, an explanation is given at the spread title page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation.

Regarding the design of this manual CLUTCH BODY Pl'9aau,. Plate and Levar A...mbly

Looollon 1 10.11 12, 17 12, 14

3 We.at,,.,

:�·1a

I Su. 7 Pret

(Dore,.

2 PMtlU,. pliat• & lrler HNmbly LL P21·12 3 Clul:chditc

1...•➔17-+f 14---.115---t1�·_J

b ,- 7. -,e:-....

C!Nnn,:o--llom ----- --.:::-�,,. ,.,.,.,.,.,,,.,,..._,.. --�-2--Ailf,)11.ir kit: dutch rei..te

1,A

_1..

_,_.,.!n(D 001100.18 _,Nf00.2kgll

10 10

2�0f"'" (lotO.O&I00.1& M-8-t0.7

Pamk)IY

9np°""(...:urin0'"'

•

eo.(�lcd:�

Plait•

-'!>Plaatlon

Patt Ne,;.

� � .,:•m ;,,

1,0-«>&10&1

�MCl.-........onolc:MdllOCMif"

_, ---·----...

<♦�·--&·

\ .:125\

'\,/'/

.----------, moo--...... --...... ..-

15-••-•,---2 ...... ,

•tti.-•-... -.� ......

-po�.

A:tllropplot•

Unit rrm

Limit 03 ?SON (l'Hkgll 00

........ 04

0.-60flN&

8 TightAl'llng torque Location

--5

c.--

Unit mm

Tool,_,...:!._

♦ Sel'vlce prooedu,.

Service atandard• Loco!loo

• n,,,.;-,

A.: P01lior.r,g pl!) (at 2 plac.1) 0: Non-...UHble pert

ll«,(l!Ho.2tu...,11

Location

�

Kindl

LOCTTT£212

,..........,

� Spacial tool•

I PNaure IIPflngcap 9 Return spring 10 A•-• �•rplate 11 Cllfchcowr 12A....,Nlllfv•rpin 1! S�rt•wrpin 14 Bue:l'ting 15 Support_, 16 ReleaNl•wr 17 8._.hlng

·A...t,ly-

,..,.._ --"' ----"' ----"'- 4 -- �-- ,.._-.Sol� Ttn,,adl"'�bol

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m-of-•prlog

ti' p,eNU,. p4il:te 1t hM bNn NIQl'OUnd, inNtt adjLilllng WHher A oorr• opondlngtoth<J.,,.,....ofl9QIW1dlnhopo,oe_,..,_,� �and_,,. opmg 7

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•

-V:.

•

-�--•_,• .,_,._o c ._o.,_o&J_�--� 1 I

1. . ...... . Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. 1a. Names of parts show an example of the disassembly (removal) sequence. 1 b. When the assembly (installation) sequence differs from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown. 2 . ....... . Service standards are shown collectively, classified by location. 3. Tightening torques are shown collectively, classified by location. 4 ........ . Points of lubricant, fluid and sealant application are shown collectively, classified by location. 5. Special tools to be used are shown collectively, classified by location. 6 ......... When it is considered hard to understand the service procedure, just by the foregoing description, a supple mentary description of the service procedure is given.

iii

DTHIS

ANUAL

1. Illustration for disassembly and assembly or removal and installation

This shows the key No. of the part. In the text, this No. is referred to uniformly throughout.

This shows that the appropriate service proce dure is described in the text.

CLUTCH BODY /

This shows an example of the disassembly (removal) sequence.

Pressure Plate and L ver Assembly 9

suml::dy sequence 1 Strap bolt 2 Washer 3 Washer 4 Bolt 5 Lock plate

6 Support nut

7 Pressure sp�--------------

------- -- �

Cfl P00-00

[D Gr 00 8 Pressure spring cap 9 Return spring 1 O Release lever plate 11 Clutch cover 12 Release lever pin 13 Support lever pin 14 Bushing 15 Support !ever 16 Release lever 17 Bushing 01276

This shows that the service procedure is described in another section. : shows reference page within the same group.

GrOO

shows reference group within the same book.

2 Pressure plate & lever assembly P 21-12 3 Clutch disc

• - Flywheel A�onlng pin (at 2 places) 0: Non�ble part

�

• AHembly sequence

'��

16➔17➔12➔10➔9➔8➔7➔6➔5➔-4➔3➔� 14➔15➔13-_j

Repair kit: clutch release lever kit

Meaning of symbols 0 : shows that the tightening torque is specified. f('1 : shows that application of lubricant, fluid or sealant is required. 0 : shows that the part should not be reused.

'"'--------"----

No service procedure is referred to in this section, but the item can be an objective of various proce dures.

This is shown when the assembly (installation) sequence is not the reverse of the disassembly (removal) sequence.

This shows that a repair kit is available.

2. Service standards table Only the relevant service standards are shown.

Service standards Maintenance item

Location 1, 11 7

Unit: mm

Clearance between strap bolt and strap plate Pressure spring

Installed load (Installed length 49.1) -· Tilt

Standard value

Limit

Remedy

0.01 to 0.16

0.3

Replace

835 N {85 kgf}

710 N {72.3 kgf}

Replace

2.9 or less

5.0

Replace

This shows the key No. of the relevant part.

3. Tightening torque table This shows specified tightening torque .

0 Tightening torque

Unit: N · m {kgf · m}

Wet

This shows the key No. of the relevant part.

This shows that the item is to be tightened wet.

4. Lubricant, fluid and sealant table Only the relevant lubricant, fluid and sealant are shown. This shows the application point. Lubricant, fluid and sealant Location 1 10, 16

Points of application Thread area of bolt

•.

Friction surfaces of release lever plate and release lever

This shows the key No. of the relevant part.

Kinds

Quantity

LOCTITE 272

As required

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

As required

This shows the specified brand.

THIS

H 5. Special tools table

Purpose of special tools is shown.

Only the relevant special tools are shown.

� Special tools Location

Unit: mm

Part No.

Tool name and shape

Clutch installer

Application

MH061051

Removal and installation of clutch cover

MH062291

Adjust release lever heights

01277

Master plate

This shows the key No. of the relevant part.

Quote this number when placing an order for the part.

6. Service procedure This indicates a special service tool.

This shows the key No. of the relevant part.

� Removal and installation of clutch cover • Depress pressure spring 7 using � clutch installer, then remove the following parts: Strap bolt 1 , washer 2, washer 3, bolt 4, lock plate 5, support nut 6 • Loosen the clutch installer gradually, then remove clutch cover 11 when the pressure spring is fully released. • For installation, follow the removal sequence in reverse.

The key No. referred to in the text is always the same as the key No. shown in the illustration.

Servicing procedures of disassembly (removal), assembly (installation), inspection, adjustment, etc. are shown collectively.

Terms and Units The terms and units in this manual are defined as follows. • This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER&_

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING&

Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION&

Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or a better understanding.

• Front and rear The terms "front" is the fan side and "rear" the flywheels side of the engine.

• Left and right The terms "right" and "left" shall be used to indicate the side as viewed from the flywheel side of the engine.

• Terms of service standards ( 1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [ ] is the basic diameter. (2) Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired.

• Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque.

vii

THIS

H e Unit

Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Systeme International d'Unites Example: 390 N · m {40 kgf · m}

-r-- � LSI unit

Metric unit

Unit Force Moment of force Positive pressure Pressure

Vacuum pressure

SI unit {metric unit}

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N · m {kgf · m}

9.80665 N · m {1 kgf · m}

kPa {kgf/cm

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH20}

9.80665 Pa {1 mmH20}

Volume

dm3

Power

kW {PS}

0.7355kW {1 PS}

Heat quantity

J {kcal}

4186.05 J {1 kcal}

W {kcal/h}

1.16279 W {1 kcal/h}

Heat flow

{L}

1 dm3 {1 L}

Angle Temperature

Electric current

Voltage

Resistance Electric power

Unit

SI unit

Foot-pound unit

Conversion rate

Force

N (Newton)

lbf

Moment of force

N·m

ft.lbs

1 N·m

Pressure

kPa (kilopascal)

psi

1 kPa 0.145 psi 1 kPa= 0.2953 in. Hg

Volume

gal.

cm3

cu.in.

1 L= 0.2642 gal. (U.S.) 1 L= 0.220 gal. (Imp.) 1 cm3 = 0.033814 oz (U.S.) 1 cm3= 0.035195 oz (Imp.) 1 cm3 = 0.061023 cu.in.

Power

kW (kilowatt)

1 kW= 1.3596 PS

Temperature

t° C = (1.8t° C + 32) ° F

1 N= 0.2248 lbf 0.7375 ft.lbs

Mass quantity of matter

kg g

lb oz

1 kg= 2.2046 lb 1 g= 0.035274 oz

Dimension

m mm

ft. in.

1 m= 3.2808 ft 1 mm= 0.03937 in.

viii

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-2

ENGINE NUMBER AND NAME PLATE . . . . . . . . . . . . . . . . . . . . . .

00-3

PRECAUTIONS FOR M AINTENANCE OPERATION . . . . . . . . . .

00-4

TABLE OF STANDARD TIGHTENING TORQUES . . . . . . . . . . . .

00-12

00-1

ENERAL SPE

Specifications

Item 6D14

Engine model

6D14 -T

6D15 -T

6016 6016 1

-E

6016 6016 6016 6016 1 1 1

-TL

-PT

-T

-TLE

6-cylinder in-line, water-cooled 4-cycle diesel

Type

Direct injection type

Combustion chamber type

Overhead valve (OHV) type

Valve mechanism Borex Stroke mm

110x115

113 X

118x115

6557

6919

7545

Total displacement cc

17.5 500

Compression ratio Empty mass kg*

115

540

17.5

500

550

* Empty mass as measured according to Mitsubishi Motors Corporation standard.

I 17.s

560

Engine Outputs Classified By Application Engine model Application

6D14

59 (79)/1500 Intermittent rated output kW (HP) 70 (94)/1800 77 (103)/2000 82 (110)/2200 87 (117)/2500 92 (123)/2800 53 (72)/1500 Continuous rated output kW (HP) 64 (86)/1800 70 (93)/2000 74 (99)/2200 79 (106)/2500 83 (111)/2800

6D14-T Middle-speed specification

6016-T

6D16

High-speed specification

Middle-speed specification

High-speed specification 101 (136)/1500

83 (111)/1500

79 (106)/1500

71 (95)/1500

106 (142)/1500

98 (132)/1800

95 (127)/1800

85 (114)/1800

123 (165)/1800

121 (163)/1800

106 (143)/2000

103 (139)/2000

93 (125)/2000

131 (176)/2000

120 (i 61 )/2500

101 (135)/2200 111 (149)/2500

140 (188)/2200

131 (175)/2000

111 (150)/2200

151 (203)/2800

126 (168)/2800

120 (161)/2800

75 (101)/1500

72 (96)/1500

65 (87)/1500

96 (129)/1500

89 (120)/1800

86 (115)/1800

77 (103)/1800

111 (149)/1800

110 (148)/1800

96 (129)/2000

94 (126)/2000

84 (113)/2000

119 (160)/2000

118 (158)/2000

101 (136)/2500

93 (125)/2200

127 (170)/2200

109 (146)/2500

101 (135)/2500

133 (178)/2500

110 (147)/2800

137 (184)/2800

101 (136)/2200

114 (153)/2800

NOTE

The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349.

The continuous rated output allows 10% (one hour) overload operation.

00-2

139 (186)/2200

147 (197)/2500 92 (123)/1500

125 (168)/2200

EN INE NU

The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its own number. This number is required for incidental inspection of the engine. Please do not fail to mention this number to the dealers when ordering spare parts.

Engine Number

Engine number 1 is punch-marked on the left of the crankcase. 1

Name Plate

□□□ U □

Example: 6 016-

Engine model

Engine

number

The name plate is attached to the portion shown in the illustration, and in dicate the following items.

18779

TOTAL CYL VOL 6557cc (400cu. in) OUT PUT [-:--=:JD/ C-==:J rpm MITSUBISHI MOTORS CORPORATION TOKYO JAPAN

-2 3

VALVE CLEARANCE (COLD) INLET 8 EXHAUST 04mm(OOl61n) f-5-3-6-2-4 FIRING ORDER FUEL INJECTION TIMING ST0C \

1 2 3 4 5 6

Engine model Total displacement Maximum output Valve clearance Firing order Fuel injection timing

18780

00-3

INTEN

PRE

In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the customer's demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure. Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the proce dure specified by this manual.

18770

Perform maintenance work at a level area. Prepare the following. • Prepare general and special tools necessary for the maintenance work.

WARNING/!\ -��---------------

Do not attempt to use tools other than special tools where use of special tools is specified in this manuai. This wili avoid injury or damage.

Pay special attention to safety when removing or installing heavy items such as engines, transmissions. When lifting up heavy items using cables, pay special attention to the fol lowing points: • Check the mass of the item to be lifted and use a cable capable of lifting that mass.

14194

• If you do not have the specified lifting hanger, secure the item using cable taking the point-of-balance of the item into consideration.

14195

• You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls.

00-4

00 Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in ad vance and keep confirming safety. Be careful not to accidentally bump switches or levers.

Check for oil leakage before cleaning the area having the fault otherwise y ou might miss detecting the leakage. Prepare replacement part(s) beforehand.

00014

""""'

Replace oil seals, packing, 0-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

---.......

[fO[J�(ID /

00015

�8�0 "'\ � .,, 0

On disassembly, visually inspect all parts for wear and tear, cracks, dam age, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

00016

00-5

AINTEN

PRE

Put alignment marks on part combinations before disas�embly and ar range the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where performance and ap pearance will not be affected. Cover the area left open after removal of parts to keep it free from dust.

CAUTION,&--------------

• Take care to avoid mixing up numerous parts, similar parts, left and right, etc. $ Keep new parts for replacement and original (removed) parts sep arate.

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oil, grease, etc. for lubricant, remove the excess immediately after application with a piece of waste, etc.

CAUTION

When the specified iubricant, fluid and sealant is not available, you may use an equivalent.

00018

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries to prevent them from short-circuit ing and burning-out.

CAUTION,&--------------

Be sure to turn starter and lighting switches, etc. off before dis connecting or connecting battery terminals, because the semi conductors can be damaged.

00-6

00 Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit.

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To recon nect a lock-type connector, press the separated parts until they click to gether.

00022

When washing the vehicle, cover the electric system parts and instru ments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00023

When using an electric welder, such electronic parts that are directly con nected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit. Parts that have switches might be subject to the same danger if the switches are left on. T herefore, do not fail to observe the following. • Connect the negative terminal of the welder as near as possible to the area that is to be welded. • Disconnect the negative terminals of batteries.

To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from O volt. Do not apply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always fed the battery voltage.

14185

00-7

AINTENAN

PRECAUTI

When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.

00027

Measurement Procedures Using Connectors

and connector A between these parts 02587

Test with connectors engaged (continuity through circuit obtained) <Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof conÂ nection, or waterproof performance might be diminished causing corroÂ sion of the connector.

<Non-waterproof connector> Insert test probe C from the harness side of the connector. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.

02588

Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

00-8

00 Using male pins Touch the pins directly using test probes.

CAUTION&_-------------

Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit.

02590

Connector Inspection Procedures Visual inspection Check for loose connection and poor engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

Check for a decrease in contact pressure between the male and female terminals.

02593

Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles.

00-9

INTEN

PRE

Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the ter minals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness gently.

02594

Inspection Procedures for Blown Fuses Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present. The major causes of a short circuii are as foiiows: • Harness stuck onto the vehicle body. • Hamess sheath damaged by friction or heat. • Water in connectors or circuits. • Mistakes (accidental short circuits)

A: Battery B: Fuse C : Loaded switch D: Load E: Short circuit

r --------,

----7

•--L

-:=-

L ____ J

02596

Precautions for Handling Alternator When servicing the alternator, pay attention to the following: • Do not connect the alternator with battery polarities reversed. If the alternator is connected with reversed polarities, a large current flow from the battery to the alternator occurs, and the diode or regulator might be damaged.

04746

00-10

00 • While the engine is running, do not remove the battery terminals. If the battery terminals are removed at that time, a surge voltage is gener ated and the diode or regulator might be weakened.

• Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.

02371

• Do not splash water over the alternator. If water is directly splashed over the alternator, individual components will be short-circuited and might be destroyed.

05165

• Do not short-circuit terminal Band terminal L while running the alterna tor. If the terminals are short-circuited while the alternator is running, the diode trio might be destroyed.

04749

• Disconnect the battery terminals before quick-charging the battery. Quick-charging without disconnecting the battery terminals miQht damage the diode or regulator.

00-11

UES

NDARD Tl HTENIN

• Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise spe cified. • Threads and contact seats shall be dry. • Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply.

Hex-head Bolt and Stud Bolt Strength classification

Unit: N · m {kgf · m}

n r

y �

02154

(Stud)

5 to7 {0.5 to0.7}

2 to3 {0.2 to0.3}

4 to 6 {0.4 to0.6}

4 to6 {0.4 t o0.6}

7 to11 {0.7 to1.1 }

8 to12 {0.8 to1.2}

9 to1 4 {0.9 to1.4}

17 t o26 {1.7 to2.6}

20 to29 {2.0 to3.0}

M10

19 to28 {1.9 to2.8}

18 to26 {1.8 to2.7}

36 to 52 {3.5 to 5.5}

33 to 49 {3.3 to5.0}

45 to60 {4.5 to6.0}

41 to59 {4.3 to6.9}

M12

35 to50 {3.4 to5.0}

31 to46 {3.1 to4.7}

70 to95 {7.0 to 9.5}

65 to85 {6.5 to 8.5}

85 to110 {8.5 to11}

75 to100 {7.5 to10}

M14

60 to85 {6.0 to8.5}

55 to75 {5.5 to7.5}

120 to160 {12 to16}

110 to1 40 {11 to1 4}

130 to180 {13 to1 8}

120 to160 {12 to17}

M16

90 to130 {9.5 to1 3}

90 to120 {9.0 to12}

180 to240 {18 to24}

160 to220 {16 to22}

200 to270 {20 to27}

1 90 to260 {19 to26}

M18

1 40 to190 {14 to19}

120 to160 {12 to16}

260 to340 {25 to35}

220 to290 {22 to30}

290 to390 {30 to40}

260 to340 { 26 to35}

M20

1 90 to260 {19 to26}

1 70 to230 {17 to23}

350 to470 {36 to48}

320 to420 {32 to43}

410 to550 {41 to56}

370 to490 {37 to50}

M22

260 to340 {26 to35}

230 to300 {23 to31}

470 to640 {48 to65}

430 to570 {43 to58}

550 to740 {56 to75}

490 to670 {50 to68}

M24

340 to450 {34 to46}

290 to390 {29 to40}

630 to840 {63 to86}

540 to730 {55 to74}

730 to980 {74 to100}

630 to840 {64 to86}

Hex-head Flange Bolt Strength classification Representation Diameter symbol

Unit: N · m {kgf · m} 4T

0 0 0 0

02154

4 to6 {0.4 t o0.6}

8 to12 {0.8 to1.2}

9 to1 4 {0.9 to1 .4}

10 to1 5 {1.0 to1.5}

19 t o28 {1.9 to2.8}

22 to32 {2.2 to 3.3}

M10

21 to 30 {2.1 to3.1}

20 to28 {1.9 to2.9}

39 to58 {3.9 to6.0}

37 to53 {3.6 to5.4}

50 to65 {5.0 to6.5}

45 to65 {4.5 to6.5}

M12

38 to54 {3.8 to5.5}

35 to51 {3.4 to5.2}

80 to110 {8.0 to11}

70 to 95 {7.0 to 9.5}

90 to120 {9.0 to12}

85 to110 {8.5 to11}

00-12

Hex-head Nut

Unit: N·m { kgf·m}

Strength classification

Representation Diameter symbol

[DJ Coarse screw

Standard screw

lNJ Coarse screw

2to 3 {0.2to 0.3}

4to 6 {0.4to 0.6}

7to 11 {0.7to U}

9to 14 0.9to 1.4}

17to 26 {1.7to 2.6}

M10

19to 28 {1.9to 2.8}

18to 26 {1.8to 2.7}

36to 52 {3.5to 5.5}

33to 49 {3.3to 5.0}

M12

35to 50 {3.4to 5.0}

31to 46 {3.1to 4.7}

70to 95 {7.0to 9.5}

65to 85 {6.5to 8.5}

M14

60 to 85 {6.0to 8.5}

55 to 75 {5.5to 7.5}

1?0 to 1n0

{12to 16}

110to 140 {11to 14}

M16

90to 130 {9.5to 13}

90 to 120 {9.0to 12}

180to 240 {18to 24}

160to 220 {16to 22}

M18

140to 190 {14to 19}

120to 160 {12to 16}

260to 340 {25to 35}

220to 290 {22to 30}

M20

190to 260 {19to 26}

170to 230 {17to 23}

350to 470 {36to 48}

320to 420 {32to 43}

M22

260to 340 {26to 35}

230to 300 {23to 31}

470to 640 {48to 65}

430to 570 {43to 58}

M24

340to 450 {34to 46}

290to 390 {29to 40}

630to 840 {63to 86}

540to 730 {55to 74}

Hex-head Flange Nut Strength classification

02155

Unit: N · m {kgf · m} 4T

Repre""- sentation "'

Diame� symbol Standard screw

02155

Coarse screw

4to 6 {0.4to 0.6}

10to 15 {1.0to 1.5}

M10

21to 30 {2.1to 3.1}

20to 28 {1.9to 2.9}

M12

38to 54 {3.8to 5.5}

35to 51 {3.4to 5.2}

00-13

HTENIN Tightening torque for flare nut for general purpose

Unit: N · m {kgf · m}

Tightening torque for air piping nylon tube for general purpose {DIN ty }

Unit: N · m {kgf · m}

-0

+1.0}

-0

Tightening torque for air piping nylon tube for general purpose {SAE ty } in.

-0

00-14

15 -0

{

+1 }

Unit: N · m {kgf · m}

SPECIFICATIONS .... . . . . ........... .... . .......... . . . ...

11-2

STRUCTURE AND O PERATION 1. 2. 3. 4. 5. 6. 7.

Cylinder Head and Crankcase ................................... Valve Mechanism ............................................... Connecting Rods ............................................... Pistons ........................................................ Timing Gears .................................................. Flywheel ....................................................... Fiywi--1eei PiO ................................................. .

TROUBLESHOOTING .....................................

11-3 11--4 11-4 11ï¿½5 11-5 11-6 .. .. t::

I 1-v

11-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure ............ . .................. 2. Inspecting and Adjusting Valve Clearances ...... . ...............

11-8 11-10

CYLINDER HEAD AND VALVE MECHANISM . . . ...... . ......

11-12

PISTONS, CONNECTING RODS, AND CYLINDER LINERS ...

11-28

FLYWHEEL PTO ... . . . . . ..... . ...... . ............ . .......

11-44

FLYWHEEL . . . . . . . . ... . . ...... . . . ......... . ..............

11-48

TIMING GEARS .. . . . . . . .... . .... . . ........ . ..............

11-54

CAMSHAFT . . . .... . ... . ............... . .... . ........... . .

11-64

CRANKSHAFT AND CRANKCASE ........... . .............

11-72

11-1

SPE

Specifications

Item 6015-T

6014-T

6014

Engine model

6016

6016-E

6016-T 6016-TP

6016-TLE

6016-TL

6-cylinder, in-line, water-cooled, 4-cycle diesel

Type

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

Cylinder borexstroke

Total displacement Compression ratio

Â˘i110x115

(j)113 X 115

Â˘i118x115

6557

6919

7545

cc 17.5

16.0

17.5

16.0

Mitsubishi Diesel Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.generac-generator-engine-parts.com

11-2

17.5

STRU TURE AND

1. Cylinder Head and Crankcase <Engines with wet type cylinder liners: 6D14, 14-T, 15-T>

1 Connecting plate 2 Glow plug 3 Cylinder liner 4 0-ring 5 Crankcase 6 Water jacket 7 Piston 8 Injection nozzle 9 Cylinder head

A: Cylinder liner size mark: A, B, C • The cylinder liners 3 are a removable wet type liners. They are press-fitted into the top of the crankcase 5 and the bottom of the wa ter jacket 6. • The 0-rings 4 are provided to prevent the in_._.. ___ _ , ___ , __ .4,

81 c;';:,;:, VI vVVIOI H,

• The cylinder liners 3 and pistons 7 have size marks. The liner and piston that are paired should be of the same size mark.

01924

<Engines with dry type cylinder liner: 6D15-T, 16, 16-E, 16-T, 16-PT 16-TL, 16-TLE> 1 Connecting plate 2 Glow plug 3 Cylinder liner 4 Crankcase 5 Water jacket 1 6 Piston 7 Injection nozzle 8 Cylinder head

A: Cylinder liner size mark

Outer diameter mark: 1, 2, 3 Inner diameter mark: A, B

• The cylinder liners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fitted into the crankcase 4. • The cylinder liners 3, crankcase 4, and pis tons 6 have size marks. They should be combined as specified according to the size marks. P.11-28

01925

11-3

STRUCTURE

2. Valve Mechanism 1 2 3 4

7 8 9

10 1, 2

12 13 14 15 16

Oi926

3. Connecting Rods <6014, 15-T (A-type), 16, 16E>

Exhaust valve Inlet valve Camshaft Tappet Push rod Rocker shaft Rocker shaft spring Rocker Rocker shaft bracket Valve cap Valve cotter Upper retainer Outer valve spring Inner valve spring Valve stem seal Valve guide

• T he valve stem seals 15 are fitted onto the vaives i, 2 to controi the amount of lubricant flowing onto the sliding surfaces of the vaives 1, 2 and valve guides 16. • T he valve springs 13, 14 are unevenly pitched to prevent abnormal vibration at high speeds. To prevent the inner and outer springs from meshing with each other, the springs are wound in opposite directions. • To facilitate removal and reinstallation of the camshaft from the rear end of the crank case, the diameter of each bushing is small er toward the front of the engine. 1 Connecting rod bushing

<6014-T, 15-T (8-type), 16-T, 16-PT, 16-TL, 16-TLE>

2 Connecting rod

3 Connecting rod bearing 4 Connecting rod cap

5 Connecting rod bolt

A 3

4 13622

11-4

A: Alignment mark B: Weight mark stamp (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z: <except 6D16-TLE>) (A, B, C, D, E, F: <6D16-TLE>)

11 4. Pistons A: Part number B: "T" mark <6014-T, 15-T, 16-T, 16-PT, 16-TL, 16-TLE> C: Size mark (A, B, C: <6014, 14-T, 15-T>) (A, 8: <6016, 16-E, 16-T, 16-PT, 16-TL, 16-TLE>) D: Weight mark .6.: Front mark 16936

5. Timing Gears 1 Camshaft gear 2 No. 2 idler gear 3 No. 1 idler gear 4 O!! pump gear 5 Crankshaft gear 6 Air compressor drive gear or injection pump drive gear 7 No. 1 idler gear 8 PTO idler gear <models with flywheel PTO> 9 PTO idler gear <models with flywheel PTO>

, ),

s---------/

, ,,..,,,, .,,,/

eJ);

-------.'---.

�t

16937

-- ·-1

c--1 tv

Each gear is stamped with a timing gear align ment mark ("1 ", "2", "3", or "4") to facilitate reas sembly.

,..-1

�

�-L

5 '4 16938

11-5

STRU TURE AN 6. Fl

heel 1 Flywheel 2 Pilot bearing 3 Ring gear A: Angle scale, cylinder number

01934

7. Flywheel PTO 1 Flange 2 PTO shaft 3 PTO idler shaft 4 Flywheel housing 5 Crankshaft gear 6 No. 1 idler gear 7 PTO idler gear 8 PTO idler gear 9 PTO gear The flywheel PTO is fitted onto the top of the flyÂ wheel housing 4 and is driven by the crankshaft gear 5.

01935

11-6

UBLESH Symptoms � �� Q)

�

-s -s0

·o

-�

�

Remarks

�

Possible causes

....J

Incorrect oil viscosity

Gr 12

Incorrect/defective fuel

Gr 13

Incorrect valve clearance Defective cylinder head gasket

0 0 0 0

Worn va1vetvaive seat, and carbon depu::sib

Weakened valve spring

(~, \_)

Worn/damaged piston ring(s)

0 0 Gr 13 0 Gr 13 0 [l]Gri4 0 0 0 [O Gr 13 [1]Gr 13 0 Gr 15 0 Gr 15 0 (' Gr 15 0

Worn/damaged piston ring groove(s) Incorrect injection timing Defective injection pump Defective cooling system Defective injection nozzle(s) Air trapped in fuel system Clogged air cleaner Clogged muffler Defective turbocharger

<l:

0 0 0 0 0

,,_)

Incorrectly fitted pipe(s)/hose(s)

()

Gr 13

Injection pump, alternator, or other auxiliary device(s) defective/incorrectly fitted

Gr 13, 54

Loose/damaged V-belt

Gr 14

Incorrectly fitted crankshaft pulley

Defective air cleaner or muffler

()

Defective valve spring(s) Incorrect lubrication of rocker shaft bracket

0 0 0

Incorrect backlash in timing gears

Incorrect lubrication of timing gear peripheries and idler shafts Worn connecting rod small end bushing and piston pin

0 0

Worn/damaged crankshaft pin and connecting rod big end bearing

(' \_)

Worn/damaged crankshaft journal and main bearing Excessive end play in crankshaft and camshaft

0 0

Worn tappet(s) and camshaft

Defective rocker shaft and bracket

\_/

Gr 15

11-7

DJUST ENT

N-VEHICLE INSPECTI 1. Measuring Compression Pressure Service standards Maintenance item

Location

Each cylinder (at 200 rpm)

Compression pressure

Standard value

Except 6D16-E 6D16-E

limit

Remedy

2550 kPa {26 kgf/cm2 } 1960 kPa {20 kgf/cm2 } 2940 kPa {30 kgf/cm2 }

Cylinder-to-cylinder pressure difference

390 kPa {4 kgf/cm2 }

� Special tools

Inspect

Unit: mm Part No.

Tool name and shape

Location

Inspect

Compression Gauge Adapter

' <j) 9 _".::-< 16Wx1 �

MH061461

Application

Measuring compression pressure

f><"·,

Centre distance 46

01942

Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take mea surements regularly and keep track of changes; an overview of pressure variations can be useful in fault diagnosis. During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly as piston rings, valve seats, and other parts fit snugly in position. T he pressure will then normalize as parts wear. • Before inspections, check that the engine oil, starter, and battery are normal. • Warm up the engine until the coolant temperature reaches 75 to 85 °C. • Tum off all lights and auxiliary devices. • To prevent injection of fuel while cranking the engine by the starter, perform the following steps. • Set the stop lever of the injection pump governor to the stop position. <Mechanical governor> • Remove fuse 1 shown in the diagram below. For the terminal arrangement of the engine ECU, refer to Gr. 13E. <Elec tronic governor> Starter SW

Engine ECU STARTER SW S) C3 STARTER SW(MH

ECU main power relay

,---. $--1-+---+---<r--;:;;-----·--t-'T

CB STARTER SW(Ml-2 C7 MA[N RELAY-1 DB MAIN RELAY-2 013 ECU POWER +VBH Dl ECU POWER(+VB)-2 02

Battery ®47396

11-8

11 • Remove the injection nozzle A. Gr 13A

CAUTION

Cover the mounting holes and injection pipes to prevent the entry of dust and dirt.

�---·--·------·-

01938

• Cover the injection nozzle mounting hole B with a cloth C. Then, turn the engine over with the starter and check that no foreign matter ad heres to the cloth. \Al I\ D MI M f"! /a\ ··-· 11,ii11,ii-Lil

If any cylinder is cracked, coolant, engine oil, and fuel wm enter the cylinder thivugh the crack. When the engine is turned over, these substances will spray out of the nozzle mounting hole Bat a high temperature. For safety, move away from the nozzle mount ing hole before turning over the engine.

01939

• Fit the� Compression Gauge Adapter onto an injection nozzle mount ing hole Btogether with a nozzle gasket. Then, connect the compres sion gauge 1. • Turn the engine over and measure the compression pressure. • Measure the compression pressure in every cylinder and determine the pressure differences between cylinders. • If any compression pressure or cylinder-to-cylinder pressure differ ence exceeds the specified limit, pour a little engine oil into the cylinder via the injection nozzle mounting hole B then take the measurement again. • If the compression pressure increases, there may be wear or dam age on piston rings and inner surfaces of cylinders. • If the compression pressure does not increase, valves may be seized or incorrectly seated, or the cylinder head gasket may be de fective.

11-9

N-VEHICLE INSPECTI

ND ADJUST ENT

2. Inspecting and Adjusting Valve Clearances Service standards

Unit: mm

0 Tightening torques

Unit: N · m {kgf · m}

Valve clearances should be checked and adjusted when the engine is cold. <Without flywheel PTO> 16

[Inspection] • Bring piston No. 1 or piston No. 6 to the top-dead-centre (TDC) position of its compression stroke. To do this, crank the engine until the "1.6" mark inscribed on the flywheel is aligned with the pointer A in the fly wheel housing inspection window. (If the engine has a flywheel PTO, align the pointer A with the "O" mark inscribed on the torsional damper.)

NOTE

Pistons whose push rods are not pushing up their rockers are at top-dead-centre (TDC) of their compression strokes.

OZ:-

Ot-- 0

__LuJ..LluLw.1..1 tJ_....J.

• When piston No. 1 or piston No. 6 is at the TDC position of its compres sion stroke, measure the clearance B of every valve marked "O" in the following table. Piston No. Valve arrangement

In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

No. 1 piston at TDC of compression stroke

0 0 0

No. 6 piston at TDC of compression stroke

NOTE

0 0

To measure the clearance, insert a feeler gauge 1. T he gauge should be able to move in the gap, albeit not loosely. Accurate measurements cannot be taken if the gauge moves loosely in the gap.

11-10

11 • If any measurement is out of specification, make adjustments as fol lows: [Adjustment]

• To adjust the valve clearance B, loosen the lock nut 2 and turn the ad justing screw 3 until the feeler gauge 1 moves more stiffly in the gap. • After adjusting the clearance, tighten the lock nut 2. At this time, use a screwdriver C to stop the adjusting screw 3 from turning. Next, insert the feeler gauge 1 once more to confirm that the clearance B is correct.

1'1621

Generac Engine 0D5703 Reference Mitsubishi 6D16-T 6D162PT 6D162PT041 Engine Maintenance Kit # ME051720 Includes: thermostat, thermostat gaskets, valve cover gasket, oil filters, air filters, fuel filters, V-belts, glow plugs, Install new thermostat and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, install new valve cover gaskets, Install new filters, Install new V-belts. Install new glow plugs. Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

11-11

CYLIN ER HE

04134

• Disassembly sequence 1 Joint

8 Cylinder head bolt 9 Rocker and bracket assembly

2 Oil filler cap

3 Bolt 4 Plate 5 Rubber 6 Rocker cover gasket 7 Rocker cover

P.11-16 10 Cylinder head and valve assem bly [O P.11-20 11 Cylinder head gasket

12 Push rod 13 Tappet

*: Crankcase [I� P.11-72 �: Locating pin 0: Non-reusable part

• Assembly sequence Follow the disassembly sequence in reverse.

Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

11-12

11 Service standards

Unit: mm

12 13,*

Standard value (Basic diameter in [ ])

Maintenance item

Location

Push rod runout Tappet-to-crankcase clearance

Remedy

0.4

Replace Replace tappet

6D14, 14-T,15-T, 16, 16-E

(31] 0.06 to 0.10

0.2

6D16-T, 16-PT 16-TL, 16-TLE

(31] 0.03 to O 07

0.1

0 Tightening torques Location

Limit

Unit: N · m {kgf · m} Tightening torque

Parts to be tightened

Joint

29 {3.0}

Rocker cover bolt

3.9 {OA}

Cylinder head bolt (installation of rocker and bracket assembly and cylinder head and valve assembly)

Remarks

M14 bolt

78 {8} + 180°

• Wet • Can be reused up to 3 times

M10 bolt

17 {1.75} + 34 {3.5}

� Lubricant ' ,' -

Location

Specified lubricant

Points of application

Quantity

Rubber seal of oil filler cap

Engine oil

As required

Threads of cylinder head bolts

Engine oil

As required

12 13

Both ends of push rods

Engine oil

As required

Outer surfaces of tappets

Engine oil

As required

� Special tools Location

Tool name and shape

Part No.

Socket Wrench

MH063388

Application

Tightening cylinder head bolts (M14 bolt only)

01984

♦ Service procedure

[!QI Cylinder head and valve assembly [Removal] • Before loosening the cylinder head bolts 8, loosen the adjusting screw C on every rocker A that is compressing its valve spring B.

13021

11-13

YLINDER HEAD AND VA • Loosen and remove the cylinder head bolts 8 in the sequence shown. Each cylinder head bolt should be loosened a little at a time. {2i

3·

,.21

1 3· 01945

[Installation]

CAUTION&-------------

Before fitting any cylinder head bolt 8, check the punch marks A on its head. Do not use the bolt if there are more than two punch marks. The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method. Any bolt that already has three punch marks must be replaced.

®21229

• Tighten the cylinder head bolts 8 to the specified torque (M14 bolts: 78 N·m {8 kgf·m}; M10 bolts: 17 N·m {1.75 kgf·m}) in the sequence shown. Then, turn the bolts further in accordance with the following procedure. *: Tighten together with rocker and bracket assembly 1 to ,261 : M14 bolt (wet) ,27 to 32, : M10 bolt 1

0·1945

<M14 Bolts> • Before fitting the [&] Socket Wrench over a cylinder head bolt, turn the holder D counter-clockwise to tension the built-in spring. E: Socket F:Rod G: Rod (extension) • Set the socket such that the built-in spring force forces the rod G against the rocker shaft bracket, an injection pipe, or another nearby part. • On the holder D, select the inscribed line H that is easiest to see. • Using the selected line as a reference, turn the socket E 180 ° clock wise. (One gradation on the scale J represents 5 ° .)

CAUTION&-------------

Since the M14 cylinder head bolts 8 utilize the plastic region tight ening method, they must not be tightened further after this proce dure.

12825

11-14

11 <M10 Bolts> • After fitting the M14 cylinder head bolts 8, tighten the M1 O bolts to the spencified torque (34 N · m {3.5 kgf · m}) in the sequence shown.

01945

[!] Cylinder head gasket [Removal]

CAUTION,&-------------

When removing the cylinder head gasket 11, be careful not to scratch the cylinder head and valve assembly 10 and the crank case*·

[Fitting] • Fit the cylinder head gasket 11 onto the crankcase

* as shown.

13582

� Push rod runout If any measurement exceeds the specified limit, replace the defective part(s).

01948

� 0 Tappet-to-crankcase clearance If any measurement exceeds the specified limit, replace the defective part(s).

11-15

CYLINDER HE Rocker and Bracket Assembly • Disassembly sequence

07----i

1 2 3 4

�

5 6

7 8

9 10 11

12 13 14

Rocker assembly Rocker bushing Lock nut Adjusting screw Rocker No. 6 rocker shaft bracket Set screw No. 5 rocker shaft bracket No. 4 rocker shaft bracket No. 3 rocker shaft bracket No. 2 rocker shaft bracket No. 1 rocker shaft bracket Rocker shaft spring Rocker shaft

• Assembly sequence Reverse the order of disassembly. 13022

Service standards Maintenance item

Location

2, 14

Unit: mm

Rocker bushing-to-rocker shaft clearance

Standard value (Basic diameter in [ ])

Limit

Remedy

(24] 0.01 to 0.08

0.12

Replace

0 Tightening torques

i�

Unit: N · m {kgf · rn}

Lubricant

� Special tools Location

11-16

Unit: mm Tool name and shape

Rocker Bushing Puller

Part No.

MH061777

Application

Removing and installing rocker bushings

11 ♦ Service procedure

W � Rocker bushing and rocker shaft [Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

01952

Rocker bushing [Removal]

12994

2 C

[Installation] • Align the oil hole A in the rocker bushing 2 with the oil hole Bin the rock er 5. • Position the notch C and seam Don the rocker bushing 2 as shown. • Install the rocker bushing 2 into the rocker 5 from the chamfered side F.

D 12995

[]] [fil to�

� Installing rocker shaft brackets and rocker shaft

Rocker shaft brackets Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions. A: Oil hole B: Threaded hole (for MS rocker cover bolt) C: Threaded hole (for M6 set screw) D: No threaded hole

13023

11-17

CYLINDER HE Rocker shaft

Align the oil hole Gin the No. 6 rocker shaft bracket 6 with the oil hole H in the rocker shaft 14. G

13024

11-18

11-19

YLINDER HE

NOVA

Cylinder Head and Valve Mechanism <Without glow plug>

20300

01955

• Disassembly sequence 1 Valve cap 2 Valve cotter 3 Upper retainer 4 Outer valve spring 5 Inner valve spring 6 Valve stem seal 7 Exhaust valve 8 Inlet valve

9 Injection nozzle [1J Gr 13 10 Dust seal

11 Nozzle tip gasket

12 Nut <With glow plug>

13 Connecting plate

16 Inlet valve guide

17 Exhaust valve seat

18 Inlet valve seat 19 Stud

20 Cylinder head

[I] Gr 54

0: Non-reusable part

14 Glow plug <With glow plug> 15 Exhaust valve guide

CAUTION&_------------------------

The injection nozzles 9 and glow plugs 14 project from the bottom surface of cylinder head 20. Take care not to damage them.

• Assembly sequence Follow the disassembly sequence in reverse.

ll-20

Mitsubishi 6D16 PT Engine Parts www.6D16.com Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone 269 673 1638

11 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

6014, 14-T, 15-T, 16, 16-E

67.0

64.0

Replace

6O16-T,16-PT, 16-TL,16-TLE

68.3

65.3

330 N {33.5 kgf}

290 N {29.7 kgf}

390 N {40.0 kgf}

350 N {35.5 kgf}

Maintenance item

Location Outer valve spring

Free length

6014,14-T,15-T,16, Installed load (at 47.8 installed 16-E length) 6O16-T, 16-PT, 16-TL , 16-TLE Squareness Inner valve spring

Free length

Squareness

Inlet valve

6O16-T, 16-PT, 16-TL,16-TLE

65.1

61.5

92 N {9.4 kgf}

78 N {8.0 kgf}

6014, 14-T, 15-T, 16, i6-E

18 20

155 N {15.8 kgf}

130 N f◄ r, A l,~ll \ I ,J."T "°81 f

2. 0

! Replace

2.5

¢i 8.93 to 8.94

(j) 8.85

Replace

1.3 to1.7

2.0

Inspect every location

Valve margin

1.5

1.2

Reface or replace

Seat angle

45°

Stem outside diameter Sinkage from cylinder head bottom surface

Stem outside diameter

Correct ¢i 8.85

Replace

Except 6016-E

1.1 to1. 5

1.8

6O16-E

1.3 to1.7

2.0

Inspect every location

1.5

1. 2

45° ±15'

Exhaust valve stem-to-valve guide clearance

[9] 0.07 to 0.10

0.2

Replace

Inlet valve stem-to-valve guide clearance

[9] 0.04 to 0.06

0.15

Replace

Exhaust valve seat width

1.8 to 2.2

2.8

Correct or replace

Inlet valve seat width

1.8 to 2.2

2.8

Correct or replace

Bottom surface distortion

0.08 or less

0. 2

Correct or replace

Height from top to bottom surface

94.9 to 95.1

94.5

Replace

Sinkage from cylinder head bottom surface Valve margin

Cylinder head

0 Tightening torques Location

Replace

Seat angle

Replace

52.1

<1> 8.96 to 8.97

7, 15 8, 16

Replace

55.1

6O16-T,16-PT 16-TL, 16-TLE Exhaust valve

2.5 6014, 14-T, 15-T, 16, 16-E

6014, 14-T, 15-T, 16, Installed load (at 40.5 installed 16-E length) 6016-T, 16-PT i 6-TL, i 6-TLE

Replace

Parts to be tightened

Glow plug <With glow plug>

Exhaust manifold mounting stud

Reface or replace Correct

Unit: N · m {kgf · m}

Tightening torque 15 to 20 {1.5 to 2.0}

Remarks -

29 {3}

11-21

HANIS

YLINDER HE � Lubricant Points of application

Location

Specified lubricant

Quantity

Rocker contact surface on valve cap top

Engine oil

As required

Lip of valve stem seal

Engine oil

As required

Valve stem

Engine oil

As required

7,8

� Special tools Tool name and shape

Location

Unit: mm Part No.

A: MH061668 (with (j)42 valve lifter seat) B: MH061679

A: Valve Lifter B: Valve Lifter Hook

(j)42

Valve Stem Seal Installer

Application

Removing and installing valve cotters

9 MH061293

Installing valve stem seals

01957

7,8

Valve Lapper

30091-07500 (inlet, exhaust)

Lapping valves and valve seats

Valve Guide Remover

MH061066 (inlet, exhaust)

Removing valve guides

Valve Guide Installer

MH061998

Installing inlet and ex haust valve guides

15,16

01960

11-22

11 A: Caulking Tool Body 8: Installer Ring

----

-------------

C dimension

MH061695 MH061696

cp 49 $42

MH061693

<p 51

MH061694

qi 44

-.-.................

17,18

Application

Part No.

Tool name and shape

Location

A: MH061067 8: MH061695 <6D14, 14-T, 15-T, 16-T, 16-PT, 16-TL, 16-TLE> (Inlet) MH061696 <6D14, 14-T, 15-T, 16-T, 16- PT, 16-TL, 16-TLE> (Exhasut)

Installing valve seats

MH061693 <6D16, 16-E> (Inlet) MH061694 <6D16, 16-E> (Ex haust)

♦ Service procedures � Valve cotters

(Removal] To remove the valve cotter 2, use the l&J Valve Lifter to evenly compress the valve springs 4, 5.

2 \�f' - 4

�� --- 6 5

[Installation] To install valve cotters, follow the removal instructions in reverse.

CAUTION&_------------Do not compress the valve springs 4, 5 more than is necessary. If the valve springs are compressed excessively, the upper retain er 3 can touch the valve stem seal 6 and be damaged.

[!] []]

Installing outer and inner valve springs

Fit the outer and inner valve springs 4, 5 onto the cylinder head 20 with their painted ends downward. A: Painted end

11641

[§] Installing valve stern seals

• Apply engine oil to the lip A of the valve stem seal 6. • Install the valve stem seal 6 using the[&] Valve Stem Seal Installer. Strike the Valve Stem Installer until it sits snugly on the cylinder head 20.

01964

ll-23

CYLIN ER HE [zJ

Valve

[Inspection] (1) Valve stem outside diameter Replace the valve 7, 8 if its stem's outside diameter is below specifica tion or severely worn.

CAUTION

Whenever a valve 7, 8 is replaced, be sure to lap the valve and valve seat 17,18. [[J P.11-25.

01965

(2) Valve seat angle and valve margin Reface or replace the valve 7, 8 if the valve seat angle or valve margin exceeds the specified limits.

7, 8

A : Valve seat angle B: Valve margin

02264

[Rectification]

NOTE

• Keep grinding to a minimum. • If the valve margin is below specification after grinding, replace the valve 7, 8. • After grinding, be sure to lap the valve and 7,8 valve seat 17, 18. [O P.11-25

[zJ [1J � [!§] Valves and valve guides [Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

15,16

01967

Valve guides [Removal]

15, 16

01972

11-24

11 [Installation] Install the valve guide 15, 16 using the l&] Valve Guide Installer. Strike the Valve Guide Installer until it sits snugly on the cylinder head 20.

CAUTION

18mm

• The valve guides 15, 16 must be pressed in to the specified depth. Be sure to use the �] Valve Guide Installer for this operation. • Exhaust valve guides 15 are longer than inlet valve guides 16. Be sure to install the correct type of guide in each location.

02220

[Inspection] • Apply an even coat of minium to the valve seat 17, 18 surface A that makes contact with the valve 7, 8. • Using the � Valve Lapper, strike the valve 7, 8 against the valve seat 17, 18 once. Do not rotate the valve during this operation.

6\=

NOTE

C:.> C.:> c._:, c:;:, ------;---,____ ______,.,.--::._-:-::,�-----.._·--·-· ---------,'"'-----·---/<:.-=�:-:_-----.____

=-=-.,,

[zJ � [!ii � Valves and valve seats

.'----'"

L__/

=_/

'-1

'-o

19681

Carry out these inspections after inspecting the valves and valve guides.

• If the minium deposited on the valve 7, 8 indicates a poor contact pat tern, rectify the contact pattern as follows:

01969

[Refacing] Lap the valve in accordance with the following procedure: • Apply a thin, even coat of lapping compound to the surface A of the valve 7, 8 that makes contact with the valve seat 17, 18.

CAUTIONLL------------Ensure that no compound adheres to the stem B of the valve 7, 8.

01970

NOTE

• Start with intermediate-mesh compound (120 to 150 mesh) and finish with fine-mesh compound (200 mesh or more). • The addition of a small amount of engine oil makes lapping com pound easier to apply.

11-25

CYLINDER HE

NOVA • Using the (&] Valve Lapper, lightly strike the valve 7, 8 against the valve seat 17, 18 while turning it little by little. • Wash away the compound with gas oil or a similar fluid. • Apply engine oil to the contact surfaces of the valve seat 17, 18 and rub it in so that the contact surfaces are lubricated and mate together snug ly. • Inspect the contact pattern of the valve 7, 8 and valve seat 17, 18 once more. • If the contact pattern is still defective, replace the valve seat 17, 18.

Bl] � Valve seats [Inspection]

7,8

(1) Valve seat width If the measurement exceeds the specified limit, rectify or replace the valve seat 17, 18. A : Valve seat width 019751

NOTE

Whenever a valve seat 17, 18 is rectified or replaced, be sure to lap the valve seat and valve 7, 8. [D P.11-25

(2) Valve sinkage from cylinder head bottom surface 7,8 17, 18

If any measurement exceeds the specified limit, rectify or replace the defective part(s). B: Valve sinkage

02265

[Rectification] • Grind the valve seat 17, 18 using a valve seat cutter or valve seat grind er. • After grinding, put some sandpaper of around #400 grade between the cutter and valve seat and grind the valve seat lightly. • Use a 15 ° or 17 ° cutter to achieve the specified valve seat width A. C : Valve seat angle

CAUTION&_-------------

Ensure that grinding does not cause the valve sinkage B to ex ceed the specified limit.

• After rectification, lap the valve 7, 8 and valve seat 17, 18. [D P.11-25

11-26

11 [Removal] Valve seats 17, 18 are installed by expansion fitting. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature.

17, 18

D: Material to remove

0.5 to 1.0 mm

01973

[Installation] • Check that the valve seat hole diameters E, F in the cylinder head 20 conform with the values shown below. Unit: mm

-------------

6014, 14-T, 15-T, 16--T, ----------------------TE, 16-TL, 16-PT --------------------16-TLE --·----o2s Inlet valve seat hole (E) 4> 49 + g

---------------

01976

Exhaust vaive seat hole (F)

<P 42 +

g.025

6016-E

6016 + o3 4i51 g

q> 44 +

go2s

q> 53 g q> 46

+ go2s

• Cool the valve seat 17, 18 by immersing it in liquid nitrogen. • Install the valve seat 17, 18 in the cylinder head 20 using the �a Caulk ing Tool Body and �b Installer Ring. • After installing the valve seat 17, 18, lap the valve seat and valve 7, 8. P.11-25

01974

� Inspecting cylinder head • Measure the extent of distortion in the cylinder head's bottom surface. • If the degree of distortion exceeds the specified limit, rectify the distor tion with a surface grinder.

CAUTION

Ensure that grinding does not cause the cylinder head's top sur face-to-bottom surface distance to fall below the specified limit.

01978

Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

11-27

NNECTIN

PIST

ER LINERS • Pre-disassembly inspection P.11-30 • Removal sequence 1 Bolt

2 Lower connecting rod bearing 3 Connecting rod cap 4 Upper connecting rod bearing

5 Piston and connecting rod assembly OJ P.11-36 6 Cylinder liner 7 O-ring <6D14, 14-T, 15-T> *a: Oil pan

Gr 12

*b: Crankshaft [I] P.11-72 • Installation sequence

�01

Reverse the order of removal.

Seivice standards

2,4,*b

Standard value (Basic diameter in [ ])

Maintenance item

Location

Unit: mm

0.85 to 1.06

Connecting rod end play

0.15 to 0.45

0.6

Replace

Except 6D16-TLE

[65] 0.04 to 0.09

0.2

Replace

6D16-TLE

[70] 0.04 to 0.09

Connecting rod bearing

Oil clearance

Except 6D16-TLE

6D16-TLE

Piston and connecting rod assembly-tocylinder liner clearance Cylinder liner

Inside diameter

Inspect each location

Less than 69.5 Less than 74.5

6D14, 14-T

[i10] 0.137 to 0.159

6D15-T

[113] 0.166 to 0.138

6D16, 16-E

[118] 0.075 to 0.105

6D16-T, 16-PT, 16-TL, 16-TLE

[118] 0.136 to 0.165

Replace Replace Replace

0.03 to 0.10

6D14, 14-T

<j) 110 to 110.035

q> 110.25

Replace or grind to oversize

6D15-T

¢i 113 to 113.035

<p 113.25

Replace

6D16, 16-E, 16- T, 16-PT 16-TL, 16-TLE

<t> 118 to 118.03

<P 118.25

Replace

6D14, 14-T, 15-T

0.02 or less

6D16, 16-E, 16-T, 16-PT, 16-TL, 16-TLE

0.03 or less

Flange projection

Cylindricity

11-28

Remedy

Piston projection

Span when free

5,6

Limit

Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Replace Replace

Replace or grind to oversize Replace or grind to oversize

11 0 Tightening torques 1

Tightening torque

Parts to be tightened

Location

29 {3} + 90 ° ± 5 °

Bolt (connecting rod installation)

Unit: N · m {kgf · m} Remarks Wet

OJ P.11-31

p-G, Lubricant

� Special tools

Part No.

Tool name and shape

Location

�]

Socket Wrench

---------------

Piston Guide

MH061560

¢> 110

6O15-T

(j) 113

Installing piston and connecting rod as sembly

01984

A dimension

6014, 14-T

Unit: mm Application

<6014, 14-T> 3009 1 -08200 <6D15-T> MH061327

Installing piston and 01980 i----------------------------+------- connecting rod as sembly <6016, 16-E, 16-T, 16-PT, 16-TL , 16-TLE> A: MH061760 B: MH061658

A: Piston Guide Clamp B: Piston Guide Lever

Cylinder Liner Extractor

-------------

C dimension

<6D14, 14-T> A: MH061719

6014, 14-T

q> 109.5

6D15-T

q>112.5

<6015-T> B: MH062003

6D16, 16-E, 16-T, 16-PT, 16-TL, 16-TLE

q>117.5

<6016, 16-E, 16-T, 16-PT, 16-TL, 16-TLE> B: MH061761

<"---c

Removing cylinder liners

Cylinder Liner Installer

----------------

A dimension

6O15-T

<jl 112.5

6016, 16-E , 16-T, 16-PT, 16-TL, 16-TLE

q> 117.5

<6O15-T> MH062002 <6O16, 16-E, 16-T, 16-PT, 16-TL, 16-TLE> MH061771

Installing cylinder liners (dry type)

01983

11-29

YLINDER LINERS

PIST

♦ Service procedure • Pre-disassembly inspection (1) Piston projection from crankcase top surface

NOTE

The piston projections affect engine performance and must therefore be checked.

WARNING&------------ 01985

With 6D16, 16-E, 16-T, 16-PT, 16-TL and 16-TLE engines, the cylinder liners may rise out of position when the crankcase is turned over or the crankshaft is turned. Hold their flanges down using bolts and washers A.

• Measure the projection of each piston at two points and calculate the average of the two values. A: Front of engine • If the average value is out of specification, check the clearances be tween all relevant parts.

01986

(2) Connecting rod end play

• Measure the end play of every connecting rod. • If any measurement exceeds the specified limit, replace the defec tive part(s).

01987

(3) Cylinder liner flange projection

If any measurement is out of specification, replace the defective part(s). B : Flange projection

CAUTION6-------------

lf the cylinder liner 6 flange projection is insufficient, bearing pressure on the cylinder head gasket will be too low in the re gion of the bore, possibly causing gas to leak.

01988

Il-30

� [!] Connecting rod bearings

[Installation] Install the connecting rod bearings 2, 4 by fitting the lugs A into their r:e spective grooves.

CAUTION

The upper connecting rod bearing has an oil hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts.

[Inspection]

CAUTION.Lh_--------------

• Do not attempt to manually expand a connecting rod bearing 2, 4 if its span is insufficient. • Upper and lower connecting rod bearings 2, 4 must be replaced as a set. (1) Span when free If the span is less than the spec1t1ed requirement, replace the upper and lower connecting rod bearings 2, 4 as a set. (2) Connecting rod bearing-to-crankshaft pin clearance If the connecting rod bearing-to-crankshaft pin clearance exceeds the specified limit, replace the defective part(s).

01996

01997

Installing piston and connecting rod assembly

CAUTION

• Ensure that the piston ring gaps A remain in their correct posi tions. l P.11-41 • Take care not to damage the piston crown B (the area that forms part of the combustion chamber). • Ensure that the connecting rod does not touch the oil jet C. 11650

11--31

YLINDER LINERS

PIST

• With the piston's "S' front mark facing the front of the engine, install the piston and connecting rod assembly in accordance with the following procedure.

",Ll."

D: Front of engine

03384

<6D14, 14-T, 15-T>

02009

<6D16, 16-E, 16-T, 16-PT, 16-TL, 16-TLE> • Fit the �a Piston Guide Clamp over the piston skirt. Using the bolt E of the �b Piston Guide Lever, adjust the clamp's inside diameter such that it matches the piston's outside diameter. • Once the �a Piston Guide Clamp is adjusted properly, remove it from the piston and smear engine oil over the following items: • Outside of piston • Inside of the �a Piston Guide Clamp • Cylinder liner 11651

F: �a Piston Guide Clamp tightening direction

02011

• With the piston installed, align the mating marks Fon the connecting rod and connecting rod cap 3 and tighten the bolts to the specified torque. Then, tighten the bolts 1 further in accordance with the follow ing procedure.

01990

11-32

11 • Before fitting the �l Socket Wrench over a bolt, turn the holder G count er-clockwise to tension the built-in spring.

r �

H: Socket J: Rod K: Rod (extension)

01991

• Set the socket wrench such that the built-in spring force forces the rod K against the crankshaft. • On the holder G, select the inscribed line L that is easiest to see. • Using the selected line as a reference, turn the socket H 90 ° ± 5 ° clock wise. (One gradation on the scale M represents 5 ° .)

NOTE After fitting the connecting rod caps 3, inspect the following items: • Connecting rod end play ( P.11-30) 116521

•

Pi�tnn (1,1 ·-�·· T1I P.11-30), - - - ·- -· - nrniA�tinns 1·- . - II - -

[]] W Piston-and-connecting rod assembly and cylinder liners [Inspection]

20 mm or more

E E

;

m �

01999

75.1 mm

<6D14, 14-T, 15-T> • If the cylinder section inside diameter of the cylinder liner 6 exceeds the specified limit, remove the cylinder liner from the crankcase and rebore it to oversize. Also replace the piston and piston rings with ones suit able for the oversized cylinder liner inside diameter.

CAUTION Even if only one cylinder requires boring, bore every cylinder to the same oversized inside diameter.

A: Measuring direction of cylinder liner bore (crankshaft axis direction) B: Measuring direction of cylinder liner bore (perpendicular to crank shaft axis) C: Measuring position of piston diameter (perpendicular to piston pin hole axis)

• Even if the cylinder section inside diameter of the cylinder liner 6 is with in the specified limit, the piston and piston rings must be replaced if the piston-to-cylinder liner clearance is out of specification. [Use of oversize pistons] • Oversizes available: 0.50 mm, 0.75 mm, 1.00 mm (three sizes in total) • To determine the required oversize, measure the inside diameter of ev ery cylinder and find the cylinder of the largest inside diameter. Select an oversize most suitable for the diameter. • Measure the outside diameter C of the oversize piston to be used. • Bore all the cylinder liners to achieve the specified nominal piston-to cylinder clearance. Diameter after boring (tolerance± 0.005 mm) Oversize piston diame ter C (measurement) + Piston-to-cylinder clearance (nominal range central value) - 0.02 mm (honing margin)

11-33

ND CYLINDER LINERS

PIST

• After boring, hone-finish the cylinder liner to the final diameter (toler ance± 0.005 mm). Final diameter (tolerance± 0.005 mm) Oversize piston diameter C (measurement)+ Piston-to-cylinder clearance (nominal range central value)

CAUTION&_--------------

• Honed surface roughness: 2 to 4 µm • Honing cross-hatching angle: 15 to 25 ° (half angle) • Squareness of cylinder bore: 0.05 mm

• Check the piston-to-cylinder clearance. Cylinder liners

[Removal]

NOTE

If any cylinder liner 6 must be reused after removal, make an align ment mark with paint and use this mark to reinstall the cylinder liner in its original position.

02000

[Installation] 6

Apply soap suds G to the cylinder liner 6. Taking care not to twist the 0rings 7, insert the cylinder liner into the crankcase.

CAUTION&_--------------

• Size marks H are provided on the cylinder liner 6 and piston. When the cylinder liner is replaced, the new one must bear the same size mark as the piston. 02001

A--------A B B

11-34

02002

J: Cylinder liner size mark K: Piston size mark • After installation, check that the O-rings 7 are not twisted.

11 <6D16, 16-E, 16-TLE> 76.1 mm <6D15--T, 16-T, 16-PT 16-TL> 75.1 mm

<6015-T, 16, 16-E, 16-T, 16-PT, 16--TL, 16-TLE> If any clearance is out of specification, replace the defective part(s). D: Outside diameter measurement position E: Direction of crankshaft axis F: Perpendicular to crankshaft axis

NOTE

The cylinder liners are of a thin design and cannot be bored to oversize dimensions. To prevent deformation of the cylinder lin ers, do not remove them except for replacement.

185 mm or more

03375

75 mm or more 20 mm or more I

02003

Cylinder liners [Removal]

NOTE

If any cylinder liner 6 must be reused after removal, make an align ment mark with paint and use this mark to reinstall the cylinder liner in its original position.

02004

• Apply engine oil to the outside suriace of the cylinder liner 6. • Insert the cylinder liner into the crankcase and press it into position us ing the� Cylinder Liner Installer. Push down evenly on the entire up per surface of the Cylinder Liner Installer.

CAUTION

02005

• Size marks L are provided on the cylinder liner 6, piston, and crankcase (6 places). When the cylinder liner is replaced, select the proper one according to the size marks on the crankcase and the piston, as shown in the illustration. M: Crankcase size mark N: Cylinder liner size mark P: Piston size mark

02006

• The cylinder liners are of a thin design. Handle them with care, and do not subject them to hammer blows or other severe shocks.

02007

11-35

NNECTIN

PIST

DS, AND CYLINDER LINERS

Piston and Connecting Rod Assembly â&#x20AC;˘ Disassembly sequence 1 2 3 4 5

Snap ring Piston pin Connecting rod bushing Connecting rod 1st compression ring 6 2nd compression ring 7 Oil ring 8 Piston

4 r-G

â&#x20AC;˘ Assembly sequence Reverse the order of disassembly.

02012

Service standards Maintenance item

Location 2,3 2,8

4 5 to 7

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

0.1

Replace

0.05

Replace

0.05

Correct or replace Replace

Piston pin-to-connecting rod small end bushing clearnace

Except 6016-TLE

[38] 0.02 to 0.05

6O16-TLE

[42] 0.02 to 0.05

Piston pin-to-piston clearance

Except 6O16-TLE

[38] 0.004 to 0.02

6O16-TLE

[42] 0.004 to 0.02

Connecting rod bend and torsion Piston ring end gap

1st compression ring

2nd compression ring

Oil ring

6014, 14-T, 15-T (B type)

0.3 to 0.45

1.5

6O15-T (A type)

0.3 to 0.5

1.5

6016, 16-T, 16-TL

0.35 to 0.55

1.5

6016-E, 16-PT, 16-TLE

0.35 to 0.5

1.5

6014

0.3 to 0.5

1.5

6O14-T, 15-T

0.3 to 0.45

1.5

6016, 16-T, 16-TL

0.35 to 0.55

1.5

6O16-E, 16-PT

0.35 to 0.5

1.5

6O16-TLE

0.45 to 0.6

1.5

6014, 14-T, 15-T

0.3 to 0.5

1.5

6016 , 16-E, 16-T, 16-PT, 16-TL, 16-TLE

0.35 to 0.55

1.5

Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com 11-36

Replace

OlJ 5 to 8

Standard value (Basic diameter in [ ])

Maintenance item

Location

Piston ring-to- 1st compression ring piston ring groove clearance

2nd compression ring

Limit

Remedy

6014

0.09 to 0.13

0.2

Replace

6O14-T, 15-T (B type)

0.05 to 0.10

0.15

Replace

6015-T (A type)

0.10 to 0.15

0.2

6016

0.11 to 0.15

0.2

6O16-E

0.13 to 0.17

0.2

6O16-T, 16-TL, 16-TLE

0.13 to 0.18

0.2

6014, 15-T (A type), 16, 16-E

0.05 to 0.08

0.15

6O14-T, 15-T (B type), 16-T, 16-PT 16-TL, 16-TLE

0.07 to 0.10

0.15

0.03 to 0.06

0.15

Oil ring

Replace

*6015-T (B type): wedge-shaped connecting rod small end

� Lubricant Specified lubricant

Points of application

Location

___ , ..., ..,,

{),,�ntih, '"""

Piston pin outer surface

Engine oil

Connecting rod bushing outer surface

Engine oil

As required

Bushing installation surface of connecting rod

Engine oil

As required

� Special tools Part No.

Tool name and shape

Location

Application

\ <µ 41

Connecting Rod Bushing Puller

<6014, 15-T (A type), 16, 16-E> MH06·1778

02014 -------1 Removing and installing connecting rod --------------------bushings <6O14-T, 15-T (B type), 16-T, 16-TE, Connecting 16-TL> Rod Bushing MH062023 Puller Kit <6O16-TLE> MH062556

<j> 100 to <j> 120

5 to 7

Piston Ring Tool

30091 -07 ·1 00

Removing and installing piston rings

02013

11-37

DS, AN

PIST

CYLINDER LINERS

♦ Service procedure

� @] Piston and connecting rod If the clearance exceeds the specified limit, replace the defective part(s).

♦® 2

02017

Connecting rod bushing <6D14, 15-T (A-type), 16, 16-E> [Removal] Apply the � Connecting Rod Bushing Puller to the connecting rod bush ing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) such that the bushing is pressed out of the connecting rod 4.

4 13616

�l

3 --.....___ ··A --

[Installation] • Align oil hole A in the connecting rod bushing 3 with oil hole B in the connecting rod 4. • Apply the � Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) such that the bushing is pressed into the connecting rod 4 from the chamfered side C.

NOTE

B-- l'� ��

ll-38

13617

After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play.

11 <6O14-T, 15-T (B-type), 16-T, 16-PT, 16-TL, 16-TLE> Replace the connecting rod bushing 3 using the� Connecting Rod Bush ing Puller Kit. This consists of the following parts: D: Base

02019

E: Bracket F: Puller G: Collar H: Plate J: Collar K: Nut [Removal] • Remove the bearing (if fitted) from the big end of the connecting rod 4.

�

T7 /

• Mount the connecting rod 4 on the base D and lock it in position with the bracket E and plate H. • Position the puller F and collar G as shown in the illustration. Then, slowly apply pressure of approximately 49 kN (5,000 kgf) until the con necting rod bushing 3 is pressed out.

020201

11507

[Installation] • Apply engine oil to the small end of the connecting rod 4 and to the out er surface of the connecting rod bushing 3. • Fit the collar J over the puller F, position the connecting rod bushing 3 and collar Gas shown in the illustration, and lock this arrangement to gether with the nut K. • Align the oil holes L in the small end of the connecting rod bushing 3 and connecting rod 4. Then, use a press to slowly apply pressure of approximately 49 kN (5,000 kgf) until the bushing is pressed into place. • After press-fitting the connecting rod bushing 3, ream it to achieve the specified nominal clearance between the bushing and piston pin 2.

NOTE

After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play.

Piston pin, connecting rod, and piston [Removal] • Tap out the piston pin 2 using a rod and hammer. • If the piston pin 2 is difficult to remove, heat the piston 8 in hot water or using a piston heater.

02022

11-39

ND CYLINDER LINERS

PIST

[Installation] • Apply engine oil to the piston pin 2. With the connecting rod 4 and pis ton 8 aligned as illustrated, insert the piston pin to hold these compo nents together.

A 8

A: Weight mark B: Weight mark (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z) C: Alignment mark for connecting rod cap �: Front mark 02023

• If the piston pin 2 is difficult to insert, heat the piston 4 in hot water or using a piston heater.

CAUTION&_-------------

• No piston should differ from any other piston by a weight of more than log. • The connecting rods must all have the same weight mark. • After inserting the piston pin 2, check that it turns smoothly and without play.

[]] W Piston pin-to-piston clearance

If the clearance exceeds the specified limit, replace the defective part(s).

[I] Connecting rod bend and twist • Fit the connecting rod bushing 3 and piston 2 in their respective posi tions of the connecting rod 4. • Measure the extent of bending A and twisting B in the connecting rod

• If either measurement exceeds the specified limit, replace the connect ing rod 4 or rectify it. C: Connecting rod 4 aligner (measurement device)

02039

4 02040

11-40

NOTE

• Before mounting the connecting rod 4 on the connecting rod aligner C, install the upper and lower connecting rod bearings in their respective positions. • Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. P.11-29

11 [I] to [I]

Piston rings and piston

Piston rings [Removal]

[Installation] • Fit the oil ring 7 onto the piston 8 with its side rail gaps A and the expan der spring gap B in the positions illustrated. • Fit the compression rings 5, 6 onto the piston such that the manufactur er's marks C near the gaps face upward. • Align the compression ring gaps D, E as illustrated.

��

5,6

D: 1st compression ring gap E: 2nd compression ring gap

0202a I

.0.: Front mark [Inspection]

(1) Piston ring end gap

8�

• Using the crown of a piston 8, push the piston ring 5, 6 or 7 horizon tally into a cylinder liner F for measurement. • Taking care not to move the piston ring 5, 6 or 7, measure the end gap. Replace all the rings of a piston if any gap exceeds the specified limit.

NOTE 5 to 7

02027

• To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them into the cylinder liner F using a piston 8. • Push the piston ring 5, 6 or 7 down to the bottom of cylinder lin er F; the bottom should be less worn than the top. • Piston rings 5, 6 or 7 must be replaced as a set. Never replace piston rings individually.

11-41

PIST

CYLINDER LINERS (2) Piston ring-to-piston ring groove clearance • If any measurement exceeds the specified limit, replace the defec tive part(s). • Measure the 1st compression ring 5 clearance with a thickness gauge H while pressing the ring against the piston 8 with a straight edge G.

NOTE

02025

020261

11-42

• Remove any carbon deposits from the ring groove of the piston 8 and measure the clearance around the piston's entire periph ery. • Piston rings 5, 6, 7 must be replaced as a set. Never replace pis ton rings individually.

11-43

HEEL PT

1i 1 1

16919

• Pre-disassembly inspection [[] P.11-45 • Disassembly sequence 1 Flywheel PTO head assembly [[] P.11-46 2 Shim

3 Seal cap 4 Nut 5 Cover 6 Ball bearing 7 Cotter 8 PTO idler shaft 9 PTO idler gear A • Assembly sequence Reverse the order of disassembly.

11-44

10 Spacer 11 PTO idler gear B 12 Spacer 13 Snap ring 14 Ball bearing 15 Snap ring

Q: Locating pin *: Flywheel housing

P.11-48

11 Service standards Maintenance item

Location

Unit: mm

Gear backlash

Between PTO idler gear A and No. 1 idler gear

Between PTO gear and idler gear B

Total PTO gear backlash

Standard value

Limit

Remedy

6D16, 16-E

0.08 to 0.20

0.35

Reference value

6D16-T, 16-PT

0.12 to 0.26

0.35

6D16, 16-E

0.08 to 0.20

0.35

6016-T, 16-PT

0.12 to 0.26

0.35

0.18 to 0.35

0 Tightening torques

Reference value

Rectify or replace

Unit: N · m {kgf · m} Remarks

♦ Service procedure • Pre-disassembly inspection Gear backlash • Measurement of the backlash between PTO idler gear A and No. 1 idler gear and of the total backlash should be carried out at the <)>100 pitch circle on the PTO flange A. If backlash is out of specification, adjust it using a shim 2. Shims are available in the following sizes: 0.1 mm, 0.2 mm, and 0.3 mm. 02045

• Measurement of the backlash between the PTO gear and PTO idler gear B should be carried out at the <)>100 pitch circle on the PTO flange. Hold the PTO idler shaft B steady while taking measurements. If the backlash is out of specification, adjust it using a shim 2. Shims are available in the following sizes: 0.1 mm, 0.2 mm, and 0.3 mm.

11-45

HEEL PT

Flywheel PTO Head Assembly

16921

• Disassembly sequence Seal cap Ball bearing Cotter PTO shaft 10 PTO gear

1 Split pin 2 Nut 3 Flange 4 Oil seal 5 Rear cover

6 7 8 9

11 Spacer 12 Snap ring 13 Ball bearing 14 Cover

• Assembly sequence Opposite of disassembly sequence.

Service standards

Unit: mm

Location PTO shaft end

0 Tightening torques

Unit: N · m {kgf · m}

� Lubricant Points of application

Location

Specified lubricant

Quantity

Flange splines

Wheel bearing grease [NLGI N0.2 (Li soap)]

As required

Oil seal lip

Wheel bearing grease [NLGI N0.2 (Li soap)]

As required

PTO shaft splines

Wheel bearing grease [NLGI N0.2 (Li soap)]

As required

11-46

11 â&#x2122;Ś Service procedure â&#x20AC;˘ Pre-disassembly inspection PTO shaft end play If the measurement exceeds the specified limit, replace the defective par t(s).

13618

[fil Removing PTO shaft A: Plastic mallet

Il-47

HEEL

<Without flywheel PTO> 0 11 ��/'

16923

• Disassembly sequence

1 Spacer 2 Bolt 3 Washer plate 4 Flywheel assembly 5 Pilot bearing 6 Ring gear 7 Flywheel 8 Rear oil seal 9 Rear oil seal retainer <models with flywheel PTO>

• Assembly sequence

Reverse the order of disassembly.

11-48

10 O-ring <models with flywheel PTO>

11 12 13 14

Plug Bolt <models with flywheel PTO> Flywheel housing Thrust plate <models with flywheel PTO>

*: Crankshaft P.11-72 �: Locating pin 0: Non-reusable part

11 Service standards

Unit: mm

Standard value

Limit

Remedy

Friction surface distortion

0.05 or less

0.2

Correct or rnplace

Height of friction surface

20 -

Replace

0.2

Correct or replace

0.2

Inspect or replace

Maintenance item

Location Flywheel assembly

Friction surface runout (when fitted) 13

Eccentricity of joint

0 Tightening torques 2

Flywheel mounting bolt

Plug

Bolt <models with flywheel PTO>

Location

2 8

Tightening torque

Parts to be tightened

Location

98 {10} + 150 °

Unit: N · m {kgf · m} Remarks

• Wet • Can be reused up to 3 times rJJ P.11-50

88 {9} 34 {3.5}

�-- -- ---·---- - -

Specified lubricant and/or sealant

Points of application

Quantity

Bolt threads

Engine oil

As required

Rear oil seal lip

Engine oil

As required

Flywheel mounting surface of rear oil seal <models without flywheel PTO>

Threebond 1207C

As required

O-ring

Engine oil

As required

Engine mounting surface of flywheel housing

Threebond 1207C

As required

� Special tools Location

Tool name and shape

Part No.

Socket Wrench

Application

MH062354

01984 1 ---------------------1-----------1 Fitting flywheel

Magnetic Base

MH062356

00471

11-49

HEEL ♦ Service procedure

[!] Flywheel assembly [Removal]

To remove the flywheel assembly 4, screw the mounting bolts 2 into the

removal holes A.

[Installation]

CAUTION&_-------------

1 ®36164

B D

tE �

Before installing the bolt 2, check the number of punch marks K on its head. (If there are two or less, the bolt is reusable.) The num ber of punch marks corresponds with the number of times a bolt has been tightened by the plastic region tightening method. If there are three (which means that the bolt has been tightened 3 times), replace the bolt.

• Tighten the bolts 2 to their specified torque, then tighten them further in accordance with the following procedure: • Turn the holder B of the [.g Socket Wrench counter-clockwise to ten sion the built-in spring.

C: Socket

D:Rod E: Rod (extension) 01991

• Set the socket wrench such that the built-in spring forces the rod E against the [.gb Magnetic Base. • On the holder B, select the inscribed line F that is easiest to see. • Using the selected line as a reference, turn the socket 150 ° clockwise. (One gradation on the scale G represents 5 °.)

CAUTION&_------------

Since the bolts 2 utilize the plastic region tightening method, they must not be tightened further after this procedure.

[.gb

11-50

14312

11 [Inspection]

(1) Runout • Tighten the bolts 2 to their specified torque. • if runout exceeds the specified limit, check that the bolts 2 are tight ened correctly and inspect the crankshaft* mounting surface. Then, rectify or replace the flywheel assembly 4 as required.

02055

(2) Height of friction surface If the measurement is below the specified value, rectify or replace the flywheel assembly 4. H : Height of friction surface

033491

(3) Distortion of friction surface If distortion exceeds the specified limit, rectify or replace the flywheel assembly 4.

NOTE

If any abnormality is evident on the ring gear 6, replace the ring gear before making inspections.

02054

\ &t111

t:bn cP

[Rectification) Grind the friction surface such that its height H remains greater than the specified minimum. The friction surface must remain parallel with surface J with a tolerance of 0.1 mm.

03351

� Ring gear [Inspection] Inspect the ring gear 6 for damage and abnormal wear. If any defect is evi dent, the ring gear must be replaced.

11-51

HEEL [Removal] • Heat the ring gear 6 evenly with an acetylene torch or the like.

CAUTION&_-------------Be careful not to get burned.

• Remove the ring gear 6 from the flywheel 7 by tapping around its entire periphery.

·�

6 6

02057

[Installation] • Using a piston heater or the like, heat the ring gear 6 to approximately 100 ° C for 3 minutes.

CAUTION

Be careful not to get burned.

• Fit the ring gear 6 with the non-chamfered side of its teeth toward the flywheel 7. 033531

A : Chamfered side of ring gear

[fil Fitting rear oil seal

<Models without flywheel PTO> • Apply an even, unbroken bead of sealant A to the rear oil seal 8 in the position illustrated B. • Fit the rear oil seal 9 onto the flywheel housing 12 within 3 minutes of applying the sealant A.

<j)2 mm

CAUTION&_-------------

• Ensure that the sealant application position B on the oil seal 8 is clean before applying sealant. • When fitting the rear oil seal 8, hold it firmly in position to prevent spreading the sealant. • After fitting the rear oil seal 8, wait at least 30 minutes before start ing the engine. • Apply a new bead of sealant A whenever the mounting bolts of the rear oil seal 8 have been loosened. • Apply engine oil to the lip of the rear oil seal 8. • Fit the rear oil seal 8 onto the flywheel housing 13 in the direction illus trated. 8

"UP"

02059

11-52

11 <Models with flywheel PTO> • Fit the rear oil seal 8 into the rear oil seal retainer 9 in the direction illus trated by pushing its periphery evenly until the end A becomes flush with the end surface of the rear oil seal retainer 9 all around.

8 ®47289

� Flywheel housing

cj) 2 mm

[Installation] • Apply an even, unbroken bead of sealant A to the crankcase mounting surface of the flywheel housing 13. • Fit the flywheel housing 13 onto the crankcase within 3 minutes of ap plying the sealant A.

CAUTION&--------------

• Ensure that the sealant application position on the flywheel hous11704

• When fitting the flywheel housing 13, hold it firmly in position to prevent spreading the sealant. • After fitting the flywheel housing 13, wait at least an hour before starting the engine. • Apply a new bead of sealant A whenever the mountiing bolts of the flywheel housing 13 have been loosened. [Inspection] • Rotate the crankshaft and check the extent of eccentricity at the joint A of the flywheel housing 13. • If eccentricity exceeds the specified limit, carry out reassembly. • If eccentricity still exceeds the specified limit after reassembly, replace the defective part(s).

02062

11-53

16939

• Pre-disassembly inspection Cl] P.11-56 • Disassembly sequence 1 Bolt 2 No. 1 idler shaft

3 No. 1 idler gear bushing

4 No. 1 idler gear 5 Nut 6 O-ring 7 Collar 8 O-ring 9 Bolt • Assembly sequence Reverse the order of disassembly.

11-54

10 Thrust washer 11 No. 2 idler gear bushing 12 No. 2 idler gear

13 No. 2 idler shaft *a : Drive gear *b : Camshaft gear CD P.11-64 *c : Crankshaft gear [LJ P.11-72

0 : Non-reusable part

CAUTION !,.______

Since the No. 1 idler gear 4 is sup ported by the No. 1 idler shaft 2, these parts must be removed as a single unit.

11 Service standards Location

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

Between No. 1 idler gear and crankshaft gear

0.08 to 0.15

0.35

Replace

Between No. 1 idler gear and No. 2 idler gear

0.07 to 0.15

0.35

Replace

Between No. 1 idler gear and drive gear

0.07 to 0.15

0.35

Replace

Between No. 2 idler gear and camshaft gear

0.08 to 0.16

0.35

Replace

[37] 0.01 to 0.05

0.2

Replace

0.05 to 0.15

0.3

Replace

[32] 0.01 to 0.05

0.2

Replace

Maintenance item Gear backlash

2,3

No. 1 idler shaft-to-gear bushing clearance

4,12

idler gear end play

11, 13

No. 2 idler gear bushing-to-shaft clearance

0 Tightening torques

Unit: N · m {kgf · m}

� Lubricant

11-55

EARS

� S

cial tools

Unit: mm

2, 4

Part No.

Tool name and shape

Location

MH061326

Gear Puller

Application

Removing No. 1 idler shaft and gear

02065 Idler Gear Bushing Puller

-----------------_, 3, 11

No. 1 idler gear bushing

<j) 37

¢> 40

No. 2 idler gear bushing

qi 32

'··

<NO. 1 > MH062601 <No.2> MH061779

<j) 35

Removing and fitting idler gear bushings

0:?06fi

Removing No. 2 idler gear shaft

Idler Shaft Puller

♦ Service procedure • Pre-disassembly inspection (1) Gear backlash

For each gear pair, measure backlash at three or more points. If any measurement exceeds the specified limit, replace the defective part(s).

02284

(2) Idler gear end play

If the measurement exceeds the specified value, replace the defective part(s).

02069

11-56

11 []J W No. 1 idler shaft and No. 1 idler gear bushing

[Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

02576

No. 1 idler gear bushing [Removal] A: Press

025771

[Installation] • Using the r:&] Idler Gear Bushing Puller, press the No. 1 idler gear bush ing 3 into the No. 1 idler gear 4 from the side of the gear whose internal diameter is chamfered B. A: Press • After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 3. 02578

[]J []J Removing No. 1 idler shaft and No. 1 idler gear Loosen the bolt 1 by approximately 15 mm, then remove the No. 1 idler shaft 2 and No. 1 idler gear 4 as a single unit.

02070

G] [g) Installing No. 1 and No. 2 idler gears Fit the No. 1 and No. 2 idler gears 4, 12 such that their alignment marks ("1 ", "2", "3", "4") are aligned with those on the gears with which they mate. *a: Drive gear *b : Camshaft gear *c : Crankshaft gear

02074

11-57

RS IT!] � No. 2 idler gear bushing and No. 2 idler shaft [Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

No. 2 idler gear bushing [Removal] A: Press

025801

◊

[Installation]

• Using the� Idler Gear Bushing Puller, press the No. 2 idler gear bush ing 11 into the No. 2 idler gear 12 from the side of the gear whose inter nal diameter is chamfered B. A: Press

02581

• After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 11. � Removing No. 2 idler shaft

02075

11-58

RS <With Flywheel PTO>

/ 0

• Disassembly sequence

1 Bolt 2 O-ring 3 No. 1 idler gear bushing 4 No. 1 idler gear 5 No. 1 idler shaft

6 Thrust washer 7 No. 2 idler gear bushing

*b : Camshaft gear CT) P.11-64

8 No. 2 idler gear 9 No. 2 idler shaft

*d: Thrust plate

*a: Drive gear *c: Crankshaft gear Cl] P.11-72 P.11-48 0: Non-reusable part

• Assembly sequence Reverse the order of disassembly.

Service standards Location

3,5

4 7,9 8

11-60

Unit mm Standard value (Basic diameter in [ ])

Limit

Remedy

Between No. 1 idler gear and crankshaft gear

0.07 to 0.20

0.35

Replace

Between No. 1 idler gear and No. 2 idler gear

0.10 to 0.22

0.35

Replace

Between No. 1 idler gear and drive gear

0.10 to 0.20

0.35

Replace

Between No. 2 idler gear and camshaft gear

0.12 to 0.26

0.35

Replace

[40] 0.03 to 0.07

0.2

Replace

0.1 to 0.6

1.0

Replace

[32] 0.01 to 0.05

0.2

Replace

0.05 to 0.20

0.4

Replace

Maintenance item Gear backlash

No. 1 idler shaft-to-gear bushing clearance No. 1 idler gear end play No. 2 idler gear bushing-to-shaft clearance No. 2 idler gear end play

11 0 Tightening torques

Unit: N · m {kgf · m}

� Lubricant

� Special tools Location

I�---------

Unit: mm Tool name and shape

Part No.

Application

Idler Gear Bushing Puller

3, 7

No. 1 idler gear bushing No. 2 idler □ear bush-

cp 40

q>44

d> 32

d> 35

<No. 1> MH061228 <No.2> MH061779

Removing and fitting idler gear bushings

02066 1

A�

♦ Service procedure • Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more points. If any measurement exceeds the specified limit, replace the defective part(s).

02068

(2) No. 2 idler gear end play If the end play measurement exceeds the specified value, replace the defective part(s).

02077

11-61

EARS

W W No. 1 idler gear bushing and No. 1 idler shaft [Inspection]

If the clearance exceeds the specified limit, replace the defective part(s).

EB 02sa2

No. 1 idler gear bushing

D, A

[Removal] The No. 1 idler gear bushing 3 consists of two parts. Press out both parts together. A: Press

025831

[Installation] • Using the � Idler Gear Bushing Puller, press each part of the No. 1 idler gear bushing 3 into the No. 1 idler gear 4 from its respective side of the gear.

OA 4

A: Press • After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 3. 02584

[I] No. 1 idler gear end play Measure the dimensions shown in the illustration and determine the end play D using the formula shown below. If the end play exceeds the speci fied limit, replace the defective part(s). D = 72.15 mm - (A+ B + C)

02078

[!] W Installing No. 1 and No. 2 idler gears Fit the No. 1 and No. 2 idler gears 4, 8 such that their alignment marks ("1 ", "2", "3", "4") are aligned with those on the gears with which they mate. *a : Drive gear *b: Camshaft gear *c: Crankshaft gear

11-62

11 [f] [[] No. 2 idler gear bushing and No. 2 idler shaft [Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

No. 2 idler gear bushing [Removal] A: Press

02580 I

[Press fitting] • Using the� Idler Gear Bushing Puller, press the No. 2 idler gear bush ing 7 into the No. 2 idler gear 2 from the side of the gear whose internal diameter is chamfered B.

A: Press • After installation, measure the clearance again. If the measurement is below the nominal value range, ream the No.2 idler gear bushing 7. 02581

11-63

FT <With electric speed sensor> 0 40 �

t ��c

I lipi(j�

e>" � <With mechanical tachometer drive>

}lf 4

��

---

-----> "'

18061

• Pre-disassembly inspection C:0 P.1·t-66 • Disassembly sequence

1 Engine speed sensor <models

with electric speed sensor> 2 Adapter <models with electric speed sensor> Tachometer drive case <models with mechanical tachometer> 3 O-ring

4 Pulse rotor <models with electric

7 8 9

NOTE

speed sensor> Tachometer drive coupling <models with mechanical tachometer> Side cover Camshaft assembly Bolt Camshaft gear T hrust plate

• Do not remove the engine speed sensor 1 unless defects are evident. • Do not remove the camshaft gear 8 unless defects are evident. • Assembly sequence Reverse the order of disassembly.

11-64

10 Key

11 Camshaft

12 13 14 15

No. No. No. No.

4 camshaft bushing 3 camshaft bushing 2 camshaft bushing 1 camshaft bushing

*: Crankcase P.11-72 0 : Non-reusable part

11 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Location

Limit

Remedy Replace

Resistance of engine speed sensor (at 25 ° G)

2.3 ± 0.2 k!2

Camshaft assembly end play

0.05 to 0.22

0.4

Inspect each part

Camshaft

Except 6O16-E

6.901

6.40

Lobe height: 49.011 Base circle diameter: 42.110

6O16-E

7.42

6.93

Lobe height: 50.33 Base circle diameter: 42.91

7.680

7.18

Cam lift

Inlet

Exhaust

lobe

height: A I"\ ,-,/"\-,

""tC/.vV/

Base circle diameter: 41.627 Bend 11, 12 to 15

Camshaft journal-tocamshaft bushing clearance

0.02 or less

0.04

Replace

No. 1 journal

[57.75] 0.05 to 0.10

0.25

Replace

No. 2 journal

[58.00) 0.05 to 0.10

No. 3 journal

[58.25] 0.13 to 0.18

No. 4 journal

[58.50] 0.05 to 0.1 o

0 Tightening torques Location

r<i

Unit: N · m {kgf · m}

Parts to be tightened

Tightening torque

Remarks

29 ± 5.9 {3.0 ± 0.6}

Pulse rotor <models with electric speed sensor>

98 {10}

Camshaft gear mounting bolt

175{18}

Engine speed sensor <models with electric speed sensor>

4 7

Lubricant and/or sealant

Location

Points of application

Specified lubricant and/or sealant

Quantity

Engine speed sensor threads <models with electric speed sensor>

Threebond 1104J

As required

Crankcase mounting surface of side cover

Threebond 1207C

As required

Camshaft journals

Engine oil

As required

Inside surfaces of camshaft bushings

Engine oil

As required

11 12 to 15

11-65

� Special tools

Unit: mm Part No.

Tool name and shape

Location

Plug

Application

MF665007

Blanking plug for use when removing cam shaft gear

MH061326

Removing camshaft gear

MH062025

Removing and instal ling camshaft bush ings

M10 X 1.25 02082

Gear Puller

02065 and Extractor

12 to 15

�"'

A, C di� mension

8 dimension

No. 1

q> 62.00

q> 57.75

No. 2

<p 62.25

<j) 58.00

No. 3

$ 62.50

(j) 58.25

No. 4

<p 62.75

(j) 58.50

♦ Service procedure • Pre-disassembly inspection Camshaft end play If the end play measurement exceeds the specified limit, replace the de fective pa11(s).

02084

OJ Inspecting engine speed sensor <Models with electric speed sensor> • Measure the electrical resistance between terminals and • If the measurement is out of specification, replace the speed sensor 1. Gr 11

CAUTION_&------------

Check the tightening torque of the engine speed sensor 1. If the sensor is insufficiently tightened, it may not produce signals.

03674

11-66

11 W Fitting side cover

<6D14, 6D14-T, 6D15-T> <j>

• Apply an even, unbroken bead of sealant A to the side cover 5. • Fit the side cover 5 onto the crankcase within 3 minutes of applying the sealant A.

1.5 mm

�

CAUTION

5 <6D16, 16-E, 6D16-T, 16-PT, 6D16-TL, 16-TLE> A

18062

• Ensure that the sealant application surface of the side cover 5 is clean before applying sealant. • When fitting the side cover 5, hold it firmly in position to prevent spreading the sealant. • After fitting the side cover 5, wait at least an hour before starting the engine. • Apply a new bead of sealant A whenever the mounting bolts of the side cover 5 have been loosened.

[II Camshaft assembly [Removal] • When removing the camshaft assembly 6, take off the side cover 5 and support the camshaft by hand. • Remove the bolts A from the camshaft gear holes, then slowly remove the camshaft assembly 6.

CAUTION&.-------------02086

Take care not to damage the camshaft bushings 12 to 15 when rew moving the camshaft assembly 6.

[Installation] • Before installing the camshaft assembly 6, measure the end play be tween the thrust plate 9 and camshaft 11. • If the measurement exceeds the specified limit, replace the defective part(s). • With the alignment marks lined up on the camshaft gear 8 and No. 2 idler gear, fit the camshaft assembly. P.11-54

02092

(]] Camshaft gear

[Removal]

CAUTION&------------The camshaft gear 8 must be removed with the appropriate spe cial tools. Do not tap off the camshaft gear since this would dam age it.

02088

l&)a: Gear Puller l.&]b: Plug

11-67

CA SHAFT [Installation] • Fit the camshaft gear 8 onto the camshaft 11 in the direction illustrated. • Do not forget to fit the key 10.

11714

[!1] Inspecting camshaft (1) Cam lift If any base circle-to-lobe height difference is less than the required val ue, replace the camshaft 11.

D<:=J

NOTE

Since the cams are tapered, they must be measured at the posi tion A shown in the diagram.

02090

B: Lobe height C: Base circle diameter D: Front of engine (2) Camshaft bend Support the camshaft 11 at its No. 1 journal E and No. 4 journal F, then take measurements at the No. 2 journal G and No. 3 journal H. If either measurement exceeds the specified limit, replace the camshaft.

G // , / /

NOTE

Turn the camshaft 11 through one revolution. One-half of the dial indicator reading represents the camshaft's bend.

////, //

04108

[DJ to�

Camshaft and camshaft bushings

[Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

NOTE

Measure the camshaft bushings 12 to 15 with the camshaft installed in the crankcase*.

11 02093

11-68

11 Camshaft bushings

"3", "4" "1", "2" "3", "4"

Removal and installation of camshaft bushings should be carried out us ing the[;&] Camshaft Bushing Installer and Extractor. Each guide of the tool is stamped with an identification mark ("1", "2", "3", "4") in the position shown. Use correct adapter and/or guide piece to remove and install a bushing according to the table below. Bushing No. (from front of engine)

13020

Identification mark

No.1

No.2

No.3

No.4

<Components of[;&] Camshaft Bushing Installer and Extractor> A:Rod B : Camshaft bushing adapter C: Guide piece D: Nut

12 to 15

[Removal] Remove the No . 4 and No. 3 camshaft bushings 12, 13 from the rear of the engine. Remove the No. 2 and No. 1 camshaft bushings 14, 15 from the front of the engine. [;&]: Camshaft Bushing Installer and Extractor

02094

[Installation] • Identify the No. 1 to No. 4 camshaft bushings 12 to 15 from their identifi cation marks ("1 ", "2", "3", "4") in accordance with the table below. If any bushing's identification mark is unclear, identify the bushing from its in ternal diameter E.

"1", "2" "3", "4"

12 to 15

11741

Bushing No. (from front of engine)

Identification mark

Internal diameter (mm)

No.1

¢ 57.75

No.2

<!> 58.00

No.3

cj) 58.25

No.4

¢ 58.50

11-69

• Install the bushings 12 to 15 by using all components of the (&] Cam shaft Bushing Installer and Extractor (rod A, camshaft bushing adapter B, guide piece C and nut D). • Install the camshaft bushings 12 to 15 in the following order: No. 3, No. 4, No. 2 and No. 1.

NOTE

Install the No. 3 and No. 4 camshaft bushings 12, 13 from the rear of the engine. Install the No. 1 and No. 2 camshaft bushings 14, 15 from the front of the engine.

• Ensure that the oil holes F in the No. 1 and No. 4 camshaft bushings 15, 12 are aligned with the oil holes Gin the crankcase. With the No. 4 camshaft bushing, ensure also that the longer oil hole H is toward the rear of the engine. J: Bushing clinch joint (&]: Camshaft Bushing Installer and Extractor

04109

Jl-70

11-71

NKSH

ND CRANKCASE

0 7

18070

• Pre-disassembly inspection CI] P.11-75 • Disassembly sequence

1 Bolt 2 Crankshaft pulley

3 Bolt 4 Torsional damper 5 Front cover assembly 6 Front oil seal 7 Front cover 8 Bolt 9 Lower main bearing

NOTE

10 11 12 13 14

Main bearing cap T hrust plate Crankshaft assembly Front oil seal slinger Rear oil seal slinger <models without flywheel PTO> Sleeve <models with flywheel PTO> 15 Crankshaft gear

16 Crankshaft 17 Upper main bearing 18 Crankcase 0 : Non-reusable part

Do not remove front oil seal slinger 13, rear oil seal slinger (or sleeve) 14 and crankshaft 15 unless faulty.

• Assembly sequence Reverse the order of disassembly.

11-72

11 Service standards

Unit: mm

9, 17

Standard value (Basic diameter in [ ])

Limit

Remedy

Except 6015-T (with dry cylinder liners)

[84] 0.05 to 0.10

0.15

Replace

6015-T (with dry cylinder liners)

[80] 0.05 to 0.10

Less than 85.5

Replace

End play

0.10 to 0.25

0.4

Replace

Bend

0.05 or less

0.1

Correct or replace

Roundness

0.01 or less

0.03

Cylindricity

0.006 or less

Correct or replace

0.07 er !css

0.2

Maintenance item

Location Main bearing

Oii ciearance

Span when free

Crankshaft

Pin and journal

Disiuriiu11 011,;rct11r-1,;ctS8 top Si.ffface

0 Tightening torques

Aonbf"o

. ·-r--·---

Remarks -

Tightening torque

Crankshaft pulley mounting bolt

185 {19}

3 8

Torsional damper mounting bolt

67 {8}

Main bearing cap mounting bolt

67 {8} + 90 °

• Wet Can be reused up to 3 times [I] P.11-76

•

� Lubricant and/or sealant Points of application

Location

5 6 8 9,17 14

Unit: N · m {kgf · m}

Parts to be tightened

Location

Correct or replace

Specified lubricant and/or sealant

Quantity

Crankcase mounting surface of front cover assembly

T hreebond 1207C

As required

Front oil seal lip

Engine oil

As required

Bolt threads

Engine oil

As required

Main bearing inside surfaces

Engine oil

As required

Apply inner surface of sleeve <With flywheel PTO>

Engine oil

As required

11-73

NKSH � Special tools

Unit: mm Part No.

Tool name and shape

Location

Main Bearing Cap Extractor

Application

MH061189

Removing main bearing caps

MH061560

Fitting main bearing caps

Front Oil Seal Slinger Installer

MH062710

Installing front oil seal

Rear Oil Seal Slinger Installer

MH061470

Installing rear oil seal slinger <Without flywheel PTO>

MH062037

Installing rear oil seal sleeve <With flywheel PTO>

MH061326

Removing crankshaft gear

MB x 1.25 02097 10

Socket Wrench

01984

(j) 105.4 02051 14

Sleeve Installer

(jl 110

®47290

Gear Puller

02065

11-74

11 ♦ Service procedure • Pre-disassembly inspection Crankshaft assembly end play If the measurement exceeds the specified limit, replace the defective part(s).

02098

[!] Torsional damper <Viscous type> CAUTION.&-------------

Leakage of silicon oil from the caulked seam A can cause the vis cous-type torsional damper to stop functioning. Note the follow ing points: • Check that the caulked seam is free of gouges and other dam-

I 11 I

�no -;:;;,-· • Do not submit the torsional damper to shock by striking it with a hammer or dropping it. • Do not roll the torsional damper or stack it with other units.

[[) Installing front cover assembly • Apply an even, unbroken bead of sealant A to the mating surface of the front cover assembly 5 to be mounted to the crankcase 20. • Fit the front cover assembly 5 onto the crankcase 20 within 3 minutes of applying the sealant A.

A \ \

CAUTION

0 11729

• Ensure that the sealant application surface of the front cover as sembly 5 is clean before applying sealant. • When fitting the front cover assembly 5, hold it firmly in position to prevent spreading the sealant. • After fitting the front cover assembly 5, wait at least an hour be fore starting the engine. • Apply a new bead of sealant A whenever the mounting bolt of the front cover assembly 5 have been loosened.

W [!zl Main bearings [Installation] Install the main bearings 9, 17 such that their lugs A fit into the corre sponding grooves.

CAUTION

The upper main bearing 17 has an oil hole B. The lower main bear ing 9 has no oil hole. Take care not to confuse the upper and lower parts.

11-75

NKSHAFT AND CR [Inspection]

CAUTION&--------------

• Do not attempt to manually expand either bearing 9, 17 if its span is insufficient. • Upper and lower bearings 9, 17 must be replaced as a set. (1) Span when free If either bearing's span when free exceeds the specified limit, the bear ings 9, 17 must be replaced.

(2) Main bearing-to-crankshaft clearance • Fit the upper main bearing 17 into the crankcase 18 and the lower main bearing 9 into the main bearing cap 10. Then, tighten the bolts 8 to their specified torque. • Measure the internal diameters of the main bearings 9, 17 and the outside diameter A of the crankshaft journal. If the clearance ex ceeds the specified limit, replace the defective part(s).

02104

[!Q] Main bearing caps [Removal]

[Installation] • Starting at the front of the engine B, fit the main bearing caps 10 in the order of the numbers A embossed on them and such that the numbers are in the positions illustrated. • The bolts 8 can be reused only three times. Before fitting the bolts, make a punch mark on the head of each bolt to indicate times of reuse.

CAUTION&-------------

lf any bolt already has three punch marks, it must not be reused any more; replace it with a new one.

02103

11-76

11 • Tighten the bolts 8 to the specified torque. Then, turn the bolts further in accordance with the following procedure: • Turn the holder C of the�] Socket Wrench counter-clockwise to ten sion the built-in spring.

F t �

D: Socket

E: Rod

F: Rod (extension) 01991

• Set the socket wrench such that the built-in spring force forces the rod F against the crankshaft assembly 12. • On the holder C, select the inscribed line G that is easiest to see. • Using the selected line as a reference, turn the socket D 90 ° clockwise. (One gradation on the scale H represents 5 ° .)

CAUTION&------------ 12

., '

, -

Since the bolts utilize the plastic region tightening method, they must not be tightened further after this procedure.

, , /;

128291

�\��

fill Installing thrust plates Fit a thrust plate 11 on each side of the main bearing caps 10 and at the rear end of the crankcase 18 such that the oil grooves A are on the out side. B: Locating pin

NOTE 11731

If oversize thrust plates 11 are used, they must be fitted on both sides of the bearing caps 10. Ensure that the bearing cap rear thrust plates and the rearmost thrust plate in the crankcase 18 are the same size. Note, however, that the front and rear thrust plates on each bearing cap may be of different sizes.

� Installing front oil seal slinger Using the� Front Oil Seal Slinger Installer, drive the front oil seal slinger 13 onto the crankshaft 16 until the tool's end face A is pressed firmly against the guide B.

16 !

11969

11-77

RANKSHAFT

__J_ J

Rear oil seal slinger and sleeve

[Installation] <Models without flywheel PTO> Using the �l Rear Oil Seai Siinger lnstaiier, drive ihe rear oii seai siinger 14 onto the crankshaft 16 until it is pressed firmly against the end face A of the crankshaft gear 15.

1��-

ASE

02063

<Models with flywheel PTO> If the outer surface of the sleeve 14 is scratched or grooved, replace the sleeve as follows. [Removal] Use a chisel to cut the sleeve 14, then remove the sleeve from the crank shaft gear 15.

CAUTION&_-------------C

®47291

Be careful not to damage the crankshaft gear 15.

[Installation] With the sleeve 14 set as shown (pay attention to the direction), turn the bolt A of the� Sleeve Installer as far as it goes. Do not tighten the bolt firmly. B: White paint C: Apply engine oil

� Crankshaft gear

<Models without flywheel PTO> [Removal]

CAUTION&_-------------

Do not tap off the crankshaft gear 15 since this could damage it.

�: Gear Puller 02110

[Installation] • Using a piston heater or the like, heat the crankshaft gear 15 to a tem perature of approximately 100 ° C. • Align the locating pin A on the crankshaft 16 with the notch B in the crankshaft gear 15. Then, drive the gear into position by striking its end face with a plastic mallet.

02111

11-78

11 15

<Models with flywheel PTO> [Removal] Screw the flywheel mounting bolts D evenly into the threaded removal holes C in the crankshaft 16. Alternatively, remove the crankshaft gear us ing the � Gear Puller.

"'-

CAUTION&_------------Do not tap off the crankshaft gear since this could damage it. C

02112

[Installation] • Using a piston heater or the like, heat the crankshaft gear 15 to a tem perature of approximately 100 ° c. • Align the locating pin A on the crankshaft 16 with the dowel pin B on the crankshaft gear 15. Then, drive the gear into position by striking its end face with a plastic mallet.

A 15

02113

IT§] B

Crankshaft

[Inspection] (1) Roundness and cylindricity of crankshaft journal and pin If either measurement exceeds the specified limit, replace the crank shaft 16 or grind it to undersize. A: Roundness B: Cylindricity 21871

(2) Bend • Support the crankshaft 16 at its No. 1 journal A and No. 7 journal 8. Measure the extent of bending in the crankshaft at the centre of the No. 4 journal C. • If the measurement exceeds the specified limit, replace the crank shaft.

NOTE 04110

H J

With the dial indicator applied to the centre journal, turn the crankshaft 16 through one revolution. One-half of the dial indi cator reading represents the extent of bending. [Rectification]

G D F

NOTE If the crankshaft 16 is rectified by grinding, the main bearings 9, 17 must be replaced with undersized ones. • Grind such that the centre-to-centre distance F between the journal D and pin E does not change. F ·· 57 · 5

0 025 mm + · -·0.075

02107

11-79

NKSHAFT AND CRANKCASE • Grind such that the journal width G and pin width H do not change. G: 37 mm H: 42 +g 2

• Finish the corner fillet smoothly and to the specified radius J. J: R4 ± 0.2 mm • Carry out a magnetic inspection to check for cracks caused by grinding. Also, check that the Shore hardness of the surface has not dropped be low Hs 75.

----- --

-----

Unit: mm

Crankshaft undersize dimensions

Finished journal diameter Finished pin diameter

Degree of undersize 0.25

0.50

0.75

1.00

Except 6015-T (with dry cylinder liners)

83.685 to 83.705

83 .435 to 83.455

83.185 to 83.205

82.935 to 82.955

6O15-T (with dry cylinder liners)

79.685 to 79.705

79 .435 to 79.455

79.185 to 79.205

78.935 to 78.955

Except 6O16-TLE

64.67 to 64.69

64.42 to 64.44

64.17 to 64.19

63.92 to 63.94

6O16-TLE

69.67 to 69.69

69.42 to 69.44

69.17 to 69.19

68.92 to 68.94

IIUllvv..:> 'Y'" IUlll,lty

• When grinding K, turn the crankshaft 16 counter-clockwise as viewed from its front end. The grinder L should rotate in the same direction. • When finishing N the crankshaft 16 with sandpaper or a whetstone M, rotate the crankshaft clockwise.

16 16

C><J A

02108

� Distortion of crankcase top surface If distortion exceeds the specified limit, correct it with a surface grinder.

A: Measurement positions

CAUTION&-------------

When grinding the crankcase 18, take care that the piston projec tions stay within specification.

11-80

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-2

STRUCTURE AND OPERATION 1. Lubrication System ............................................. 2. Oil Pump ...................................................... 3. Oil Filter ...................................................... . 4. Oil Cooler ...................................................... 5. Engine Oil Pressure Switch, Regulator Valve ..................... 6. Lubrication of Related Parts ....................................

TROUBLESHOOTING .................................... .

12-3 12-4 12-4 12-6 12-7 12-7

12-12

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement .......................................... 2. Engine Oil Replacement ........................................ 3. Oil Pressure Measurement ..... . ................................

12-13 12-17 12-18

OIL PAN, OIL JET, AND OIL LE VEL SENSOR . . . . . . . . . . . . . . .

12-20

OIL PUMP AND OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-22

OIL FILTER <Spin-on Type> ................................................. <Replaceable-element Type>

12-26 12-28

OIL COOLER <Except 6D16-TLE> . ....... . .................................... <6D16-TLE> ....................................................

REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-30 12-32

12-34

12-1

SPECIFIC

Item Mode of lubrication

Specifications Oil pump type

Oil filter type

Spin-on paper-filter type or replaceable-element type Shell and plate type (multi-plate type)

Oil cooler type

Turbocharged engine: API CD or above

Engine oil

Non-turbocharged engine: API CC or above Oil quantity dm3 {L}

Oil pan Oil filter

12-2

General power applications

Approx. 9.5 {9.5}

Construction machinery applications

Approx. 16 {16}

Spin-on type: A, B type

2.1 {2.1}

Spin-on type: C type, Replaceable-element type

2.3 {2.3}

STRU TURE AND

1. Lubrication System (Oil Flow) 1

ďż˝j-3--, 21

16887

1 2 3 4 5 6

7 8 9 10 11 12 13 14 15

Engine oil pressure gauge unit Main oil gallery Bypass valve Oil cooler Engine oil bypass aiarm switch Full-flow filter element Bypass filter element Check valve (built into oil filter) Bypass check valve (built into oil filter) Relief valve (built into oil pump) Oil pump Oil strainer Regulator valve Crankshaft main bearing Connecting rod bearing

16 Connecting rod bushing 17 Check valve for oil jet 18 Piston 19 Injection pump 20 Injection pump drive (or air compressor) 21 Timing gears

22 Camshaft bushing

23 Rocker bushing 24 Push rod 25 Tappet

26 Idler gear shaft No. 1

27 Idler gear shaft No. 2

28 T urbocharger <6014-T, 15-T, 16-T, 16-TL, 16-TLE> 29 Oil pan

12-3

STRUCTURE AND 2. Oil Pump

1 Crankshaft gear

2 Oil pump gear

3 Oii pump

4 Oil strainer

5 Relief valve

A: To oil filter

B: From oil pan C: To oil pan

Oil pump 3 is a gear type. It is driven by rotation of the crankshaft via crankshaft gear 1 and oil pump gear 2. Relief valve 5 is fitted to the oil pump. When the oil pump disÂ charge pressure exceeds a specified level, the relief valve reÂ turns some of the engine oil to the oil pan, thus protecting the lubrication system from excessive oil pressure. 01476

3. Oil Filter <Spin-on type (A, B type)>

1 Full-flow filter element

2 Bypass filter element 3 Engine oil bypass alarm switch 4 Check valve 5 Bypass check valve

A: To oil cooler

B: From oil pump

C: To oil pan

T his oil filter is a spin-on paper-filter type incorporating full-flow filter element 1 and bypass filter element 2. Engine oil bypass alarm switch 3 is fitted to the oil filter bracket. If clogging causes the pressure difference before and after the element to exceed a specified level, a valve inside the switch opens to allow oil to flow directly to the oil cooler. Check valve 4 is fitted to the inlet to prevent a reverse flow of oil out of the filter when the engine is stationary. In conjunction with this, bypass check valve 5 opens only when oil pressure in the bypass arrangement exceeds a specified level. As a result, the oil level in the filter is kept constant and oil reaches all parts of the lubrication system quickly when the engine is started.

12-4

12 <Spin-on type (C type)> 1 Engine oil bypass alarm switch

A B C

2 Bypass filter element

3 Full-flow filter element A: To oil pan B: To oil cooler C: From oil pump This oil filter is a paper-filter type incorporating full-flow filter ele ment 3 and bypass filter element 2.

®34244

Engine oil bypass alarm switch • If the nil filtAr AIAmAnt hecomes clogged. the flow of engine oil is restricted, causing engine parts to seize. To prevent this, engine oil bypass alarm switch 1 is fitted to the spin-on filter. • When the oil filter element becomes clogged, engine oil bypass alarm switch 1 is activated. As a result, engine oil is allowed to flow directly to the oil cooler, bypassing full-flow filter element 3. When the engine oil bypass alarm switch is activated, a warning lamp illuminates to notify the operator of the clogged oil filter element.

®34247

<Replaceable-element type> 1 Full-flow filter element 2 Bypass filter element 3 Engine oil bypass alarm switch 4 Check valve A: From oil pump

B: To oil cooler C: To oil pan

This oil filter is a replaceable-element type incorporating full flow filter element 1 and bypass filter element 2. Engine oil bypass alarm switch 3 is fitted to the oil filter bracket. If clogging causes the pressure difference before and after the element to exceed a specified level, a valve inside the switch opens to allow oil to flow directly to the oil cooler. Check valve 4 is fitted to the inlet to prevent a reverse flow of oil out of the filter when the engine is stationary. This ensures that the oil level in the filter remains constant such that oil reaches all parts of the lubrication system quickly when the engine is started.

04342

12-5

STRU TURE 4. Oi I Cooler <Except 6D16-TLE>

<6D16-TLE>

01478

1 Oil cooler cover 2 Oi! cooler element 3 Bypass valve

®34273

A: To main oil gallery B: From oil filter

• Bypass valve Bypass valve 3 is fitted to the oil cooler. When engine oil is cool and its viscosity is high, or when the oil cooler element becomes clogged and restricts the flow of engine oil, this valve opens. As a result, engine oil is allowed to flow directly to the main oil gallery, bypassing the oil cooler. A: To main oil gallery B: From oil filter <6D16-TLE>

01479

®34275

12-6

5. Engine Oil Pressure Switch, Regulator Valve 1 Crankcase 2 Engine oil pressure switch 3 Regulator valve

<Except 6016-TLE> B

\'�

.... .......

A: To oil pan B: Main oil gallery

• Engine oil pressure switch 16888

<6D16-TLE>

If the pressure of engine oil to the main oil gallery drops below a specified level, an electrical contact incorporated in engine oil pressure switch 2 closes. This causes a relevant warning lamp on the meter cluster to illumi nate, notifying the operator of the excessive pressure drop. • Regulator valve If the oil pressure in the main oil gallery exceeds a specified level, regula tor valve 3 opens to allow some of the engine oil to return to the oil pan, thereby regulating the oil pressure to specification.

I 1

®447191

6. Lubrication of Related Parts Engine oil fed to the main oil gallery lubricates the following related parts: • Main Bearing and Connecting Rod Bearing

·�

��)

�1481

1 2 3 4

Connecting rod bushing Connecting rod bearing Crankshaft Main bearing

A:Oiljet B: Connecting rod oil passage C: Main oil gallery Oil supplied via the oil passage in crankshaft 3 flows through connecting rod oil passage B to lubricate the connecting rod's small end. The oil then sprays out of oil jet A at the top of the connecting rod to cool the piston.

12-7

STRUCTURE

N • Timing gear and camshaft 1 Camshaft bushing No. 4 2 Camshaft 3 Idler gear No. 2 4 Idler gear bushing 5 Idler shaft No. 2 6 Idler gear No. 1 7 Idler gear bushing 8 Idler gear shaft No. 1 A: To rocker bushing B: From main oil gallery Engine oil flows through the inside of camshaft 2 and lubricates each cam shaft bushing.

01482

If a flywheel power take-off (PTO) is fitted, oil flows through an oil passage in the flywheel housing and sprays out of the oil jet to lubricate PTO idler gear B 12.

9 PTO idler gear A 10 Idler No. 1

11 PTO idler shaft 12 PTO idler gear B 13 Oil jet

16889

12-8

12 â&#x20AC;˘ Valve mechanism 1 Rocker shaft bracket 2 Rocker 3 Rocker shaft 4 Rocker bushing 5 Crankcase 6 Cylinder head 7 Cylinder head bolt 8 Push rod 9 Tappet 10 Camshaft

A: From camshaft bushing No. 4 B: Oil reservoir C: To oil pan After lubricating rocker 2, the camshaft bushings, and other components, oil enters oil reservoir B to lubricate the cams.

01485

â&#x20AC;˘ Check valve and oil jet 1 Piston 2 Oil jet 3 Check valve A: Main oil gallery

01487

An oil jet 2 is fitted in the lower part of the main oil gallery A for each piston. T hese oil jets cool the pistons 1 by injecting oil into them. Each oil jet is fitted with a check valve that opens and closes at specified oil pressure levels. At low engine speeds, these check valves 3 close to maintain the required volume of oil in the lubrication system and prevent reductions in oil pressure.

12-9

STRUCTURE AND

e Turbocharger <6014-T, 15-T, 16-T, 16-PT, 16-TL, 16-TLE>

1 Bearing housing

2 Snap ring 3 Piston ring

4 Bearing

A: From main oil gallery

B: To oil pan Via an oil pipe, engine oil is delivered from the main oil gallery to the bear ing housing 1 to lubricate the inside of the bearing housing. At each end of the turbine wheel shaft, piston ring 3 acts as an oil seal. 4

01488

• Injection pump 1 Injection pump 2 Governor 3 Aii cornpiesso, (or injecthx, puff1f) urive)

A: From main oil gallery B: To oil pan Engine oil that has lubricated injection pump 1 and governor 2 returns to the oil pan via the timer case, air compressor 3 (or injection pump drive), and timing gear train. • Air compressor 1 Piston 2 Connecting rod 3 Crankshaft 4 Connecting rod bushing 5 Crankcase

A: From main oil gallery B: To oil pan Engine oil from the main oil gallery splashes onto connecting rod 2 and lubricates connecting rod bushing 4. Piston 1 and the connecting rod's small end are lubricated by oil that is splashed onto them by the rotation of the crankshaft 3.

11107

12-10

12 â&#x20AC;˘ Vacuum pump Some of the oil used to lubricate the camshaft bushings is fed to the vacuÂ um pump housing via a flexible hose. After lubricating the vacuum pump vanes, this oil !eaves via an outlet at !he bottom of the housing and returns to the oil pan.

01491

12-11

UBLESH Symptoms

co co

��

� C

�

:g_

'----, t::'.

(l.) ,_

,_ ro

Q.)

w 0

Q.)

> Q.)

0 0 0 0

Gasket defective O-ring defective Oil cooler element clogged

0 0 0 0 0 0 0

u u u

Oii cooier eiemem damaged

0 0 0

Fatigue in bypass valve spring Oil pump malfunctioning

Oil pump

�

Oil cooler element installed poorly

Interference between oil pump gear and oil pump case or cover

0 0 0 0 0

Oil pipe poorly fitted Oil strainer clogged Fatigue in relief valve spring

Oil filter fitted poorly

0 0

Element clogged Oil filter

Front cover assembly timing gear case Flywheel housing

Fatigue in check valve and bypass check valve springs <A, 8 type>

O-ring defective

0 Gr11 0 [fJ Gr 11 0 Gr11 0 Gr11 0

Front oil seal defective Front cover assembly fitted poorly Rear oil seal defective Gasket fitted poorly

Fatigue in regulator valve spring

Piston cooling oil jet(s) defective

0 [fJGr11 Gr11 0

Oil working its way up into combustion chamber(s) Oil working its way down into combustion chamber(s) Oil viscosity too high Unsuitable oil quality Deterioration in oil Fuel mixed with oil

12-12

(l.)

Q..

·o

·o,

Oil cooler

()

·o

..c ,_

Q.)

�

-�

·u5

Possible causes

0) C

(/) (/) (l.)

0 0 0 0

Remarks

DJUST ENT

N-VEHI LE INSPE 1. Oil Filter Replacement <Spin-on type>

Unit: N · m {kgf · m}

0 Tightening torques

Remarks

� Special tools Location

Unit: mm Part No.

Tool name and shape

Oil Filter Wrench

MH061537

Application

Oil filter removal

01503

WARNING&. -------------

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION&.--------------

3 ®47028

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

For type A or type B oil filter, loosen drain plug 1 or oil filter drain plug 2 and air plug 3 in that order, then drain the oil out of filter 4.

®47029

12-13

12 [Installation] • Clean the surtace on oil filter head 5 that makes contact with oil filter 4. • Apply a film of engine oil to gasket area A of filter 4. • Screw oil filter 4 into oil filter head 5 until gasket area A touches the oil filter head. • From this position, tighten filter 3 by a further 1 1 /8 to 13/s of a turn. • Fit oil filter drain valve 1 or oil filter drain plug 2. • Start the engine and check that no oil leaks from gasket area A. • Check the engine oil level and add oil if necessary.

®47033

12-15

N-VEHICLE INSPECTI N AND ADJUST ENT <Replaceable-element type> 0 Tightening torques

Unit: N · m {kgf · m}

WARNING_&.-------------

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION&_-------------167681

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip; ri:md�ri11g the cooling system less effective.

With a downward-facing oil filter, loosen drain valve plug 1 and air plug 2 in that order, then drain the oil out of filter 3. [Removal] 4 Center bolt 5 O-ring 6 Filter case 7 O-ring 8 Set spring 9 Element 10 Filter bracket

16769

[Installation] Wash all components other than the element in cleaning solvent, then fit the filter in the opposite order from that in which it was removed.

CAUTION

• If O-ring 7 is twisted when fitted, it may be severed. • Element 9 cannot be washed and reused.

12-16

12 2. Engine Oil Replacement 0 Tightening torques

Unit: N · m {kgf · m} Tightening torque

Parts to be tightened

Location

Remarks

69 {7}

Oil pan drain plug

Oil filter drain valve

29 ± 4.9 {3 ± 0.5}

Oil filter drain plug

7.8 ± 2.0 {0.8 ± 0.2}

Lubricants Points of application

Location

Oil pan

General power applications

{L}

dm3

Kinds

Quantity

Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

Approx. 9.5 {9.5}

Construction machinery applications Spin-on type: A, B type

Oil filter dm3 {L}

Spin-on type: C type Replaceable-element type

-- -

r\r,-�

-:::- \[J[]� :- :----·- t"·1 \

\__

Approx. 2.1 {2.1} Approx. 2.3 {2.3}

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

11_

I,' �1 j

Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

WARNING

<Spin-on type: A type> 1

Approx. 16 {16}

CAUTION,&------------

04'0_,

<Spin-on type: B type>

®16770

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective. [Draining] • Warm up the engine, then remove oil filler cap 1. • Remove oil pan drain plug 2, oil filter drain valve 3 or oil filter drain plug 4, and air plug 5. Then, drain the engine oil.

<Spin-on type: C type> 1,

[�}1�t

®47034

. 'i

- ,,---::=- ----- ---=-=i, �+------- - -- 5

•��-�1J

4 2 <Replaceable•-element type> ·t

[Filling] Tighten oil pan drain plug 2 and oil filter drain valve 3 or oil filter drain plug 4 to their specified torques, then pour the specified quantity of engine oil into the engine.

®47096

®16772

12-17

N-VEHI LE INSPE

DJUST ENT

3. Oil Pressure Measurement <Except 6D16-TLE> Service standards Location

Maintenance item

Standard value

At no-load minimum speed

Oil pressure (at oil temperature 70 to 90° C)

At no-load maximum speed

0.1 MPa {1.0

kgf/cm2 }

or higher

0.2 to 0.6 MPa {2.0 to 6.1 kgf/cm2 }

0 Tightening torque

Limit

Remedy

Up to 0.1 MPa {1.0 kgf/cm2 }

Adjust

Up to 0.2 MPa {2.0 kgf/cm2 }

Unit: N · m {kgf · m}

� Sealant

• Remove engine oil pressure gauge unit 1.

• Fit adapter 3 onto the engine oil pressure gauge unit mounting, then fit the oil pressure gauge onto the adapter. • Warm up the engine until the oil temperature reaches 70 to 90 ° C. • Measure the oil pressure at no-load minimum speed and at no-load maximum speed. If the measured values are below the specified stan dard values, overhaul the lubrication system. • After taking measurements, fit oil pressure gauge unit 1 and tighten it to the specified torque. PT1/8

12-18

NOTE 16774

Oil pressure gauge unit 1 must be fitted with the engine cold.

12 <6D16-TLE> Service standards Location

Maintenance item Oil pressure (at oil temperature 70 to 90 ° C)

Standard value

At no-load minimum speed

At no-load maximum speed

0.1 MPa {1.0

kgf/cm2 }

or higher

0.2 to 0.6 MPa {2.0 to 6.1 kg1/cm2 }

0 Tightening torque Location

Limit

Remedy

Up to 0.1 MPa {1.0 kgf/cm2 }

Adjust

Up to 0.2 MPa {2.0 kgf/cm2 }

Adjust

Unit: N · m {kgf · m}

Parts to be tightened Engine oil pressure switch

Tightening torque

Remarks

15 to 22 {1.5 to 2.2}

Tighten with engine cold

Sealant Location 1

Points of application

Specified sealant

Wrap around thread of engine oil pressure switch

Teflon tape

Quantity 3 1 /2 turns

• Remove engine oil pressure switch 1.

2: Oil cooler

®11112

• Fit adapter 3 into the opening from which the engine oil pressure switch has been removed. Install an oil pressure gauge onto the adapter. • Run the engine until oil temperature reaches 70 90 ° C. • Measure the oil pressure at both no-load minimum and maximum speeds. If either of the measured values is below the limit pressures, overhaul the lubrication system. • Fit engine oil pressure switch 1 and tighten it to the specified torque.

NOTE ®11113

Installation of engine oil pressure switch 1 must be performed while the engine is cold.

12-19

IL LEVEL SENS R • Disassembly sequence 1 Drain plug 2 Oil pan

3 Engine oil temperature sensor 4 Check valve 5 Oil jet *: Crankcase assembly lJ] Gr 11 Q: Locating pin 0 : Non-reusable part • Assembly sequence Reverse the order of disassembly.

CAUTION,&.------

Do not tighten check valve 4 in excess of the specified torque. Excessive tight ness can cause defective operation, re sulting in scorching of the engine.

0 1---A -

� 16775

Service standards 3

Standard value

Maintenance item

Location

Resistance of engine oil temperature sensor (between ternimal c 1_, and body)

50 C

(136 .0)

48 '.t 5 .0

100 ° c

27.2 ± 2 Q

80 C

Limit

Remedy Replace

Figures in parentheses are approximate.

0 Tightening torques Location

Unit: N · m {kgf · m}

Parts to be tightened

Drain plug

Engine oil temperature sensor

Check valve

Tightening torque

Remarks

34 ± 6.9 {3.5 ± 0. 7}

34 {3.5}

69 {7}

� Sealant Location 2

12-20

Points of application Crankcase mounting surface of oil pan

Specified sealant THREEBOND 1207C

Quantity As required

12 ♦ Service procedure 2 Fitting oil pan 2 ��

�1.5mm

• Apply sealant A to the mounting surface of oil pan 2 as illustrated. Apply the sealant evenly and without breaks. • Within three minutes of applying sealant A, fit oil pan 2 onto the crank case*.

CAUTION,&.--------------

11115

• Clean the oil pan mounting surface and ensure it is free of oily substances before applying sealant A. • Carefully mount oil pan 2 exactly in the correct position. Ensure that sealant A does not spread to other areas. • After fitting oil pan 2, wait at least one hour before starting the en gine. • Reapply sealant A whenever the oil pan mounting bolts have been loosened.

[fil Engine oil temperature sensor • Place engine oil temperature sensor 3 in a container of engine oil. • Heat the engine oil until it reaches each of the temperatures in the ser vice standards table. • At each of the given temperatures, measure the electrical resistance between the engine oil temperature sensor's terminal 1 and body (2:,. • If the resistance values do not match those in the service standards table, replace the engine oil temperature sensor 3. 03868

12-21

IL STR INER

01497

• Inspection before disassembly P.12-23 • Disassembly sequence 1 Oil strainer 2 Oil pipe 3 Oil pump assembly 4 Bolt 5 Cover 6 Driven gear assembly 7 Ring

NOTE

8 Relief valve

9 Relief valve spring 10 Washer 11 Gear and case assembly 12 Shim

Gr 1 i *a: Crankcase assembly *b: Crankshaft gear [[J Gr 11 *c: Oil pump gear 0: Locating pin 0: Non-reusable part

• Do not remove parts #7 to 1 O unless they are defective. • Gear and case assembly 11 is an integrated unit and cannot be disassembled. If any defect is apparent, replace the whole unit. • Do not remove oil strainer 1 and oil pipe 2 from oil pump assembly 3 unless they are defective. Remove those three as a unit. • Assembly sequence Reverse the order of disassembly.

12-22

12 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Limit

Remedy

Clearance between drive gear shaft and inner diameter of cover

[20] 0.04 to 0.07

0.15

Replace

5, 6, 11

Clearance between driven gear shaft and inner diameter of case and cover

[20] 0.04 to 0.07

0.15

Replace

6, 11

Clearance between case and tooth tips of each gear

0.10 to 0.19

0.2

Replace

Difference between height of each gear and depth of case

0.06 to 0.11

0.15

980 to 1175 kPa {10 to 12 kgf/cm2}

5, 11

Maintenance item

Location

Relief valve opening pressure

Relief valve spring load (installed length = 30)

*b,*c

Backlash between oil pump gear and crankshaft gear

84 N {8.6 kgf}

Without PTO

0.08 to 0.18

With PTO

0.10 to 0.22

0 Tightening torque

Replace Replace

0.35

Adjust with shims

Unit: N · m {kgf · m}

♦ Service procedure • Inspection before disassembly

Measure the backlash between oil pump gear *c and crankshaft gear *b. If the amount of backlash exceeds the specified limit, adjust it with shims 12.

12 \ \

NOTE Shim 12 must have the same thickness on the left and right sides.

EB EB

[§] [§] B]

Inspection of cover, driven gear assembly, and gear and case assembly

Measure the clearance between each gear shaft and the internal diame ters of the cover and case.

01499

12-23

IL STRAINER [fil [TI] Inspection of driven gear assembly and of gear and case asÂ sembly

(1) Differences between gear heights and case depth Replace any component whose measurement is out of specification.

(2) Clearance between gear teeth and case Replace any component whose measurement is out of specification.

01501

12-24

12-25

pe>

ER <Spin-on <A type>

• Disassembly sequence 1 2 3 4 5 6 7 8 9

Oil filter drain valve <A, B type> Oil filter drain plug Oil filter [(j P.12-13 Engine oil bypass alarm switch O-ring Air plug <A, B type> Oil filter head Spacer <B type> O-ring

*a: Oil cooler [(j P.12-30 *b: Crankcase assembly 0: Non-reusable part

Gr 11

®47035

• Assembly sequence Reverse the order of disassembly.

6 3

®47036

4 0 *b 7 3/

� � 02®34249

12-26

12 WARNING_&-------------------------• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns. CAUTION&------------------------- When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

Service standards Standard value

Location

Maintenance item

Engine oil bypass alarm switch valve opening pressure

0.191

°5

+0 5

MPa {1 .9 6 kgf/cm 2}

Limit -

0 Tightening torques

Remedy Replace

Unit: N · m {kgf · m} Tightening torque

Oil filter drain valve <A, B type>

29 ± 4.9 {3.0 ± 0.5}

Remarks -

Oil filter drain plug

7.8 ± 2.0 {0.8 ± 0.2}

Engine oil bypass alarm switch

49 ± 4.9 {5.0 ± 0.5}

Parts to be tightened

Location

� Lubricant Location

Specified lubricant

Points of application

Apply thin film to oil filter gasket area

Apply to O-rings

P.12-13

Quantity

Engine oil

As required

Engine oil

As required

♦ Service procedure [}] Inspection of engine oil bypass alarm switch

11312

Carry out the following inspections and replace the engine oil bypass alarm switch 4 if the results are unsatisfactory: • With no air pressure A applied to engine oil bypass alarm switch 4, check that there is no electrical continuity between the terminal and body r2 of the engine oi! bypass alarm switch. • Starting with pressure of O kPa {O kgf/cm2 }, gradually increase the air pressure A on engine oil bypass alarm switch 4. Note the air pressure when electrical continuity appears between the terminal and body '2·. Verify that this pressure conforms with the specified standard value. B: Air pressure gauge

12-27

pe>

ER <Replaceable-element

• Disassembly sequence 1 Oil filter drain valve

2 Air plug 3 Center bolt

4 0-ring 5 Filter case 6 0-ring 7 Set spring 8 Element 9 Engine oil bypass alarm switch 10 Filter bracket 11 0-ring ""8 0

*: Oil cooler P.12-30 0: Non-reusable part • Assembly sequence Reverse the order of disassembly. 16778

WARNING

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION&-------------------------

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

Service standards Location

Maintenance item

Standard value

Engine oil bypass alarm switch valve opening pressure

145 +go kPa {1.5 +oct kgf/cm2}

Tightening torques

Location

Parts to be tightened

Tightening torque

Oil filter drain valve

29 ± 4.9 {3.0 ± 0.5}

Center bolt

54 ± 4.9 {5.5 ± 0.5}

Engine oil bypass alarm switch

49 ± 4.9 {5.0 ± 0.5}

12-28

Remedy Replace

Unit: N · m {kgf · m}

rC\ Lubricant

Limit

Remarks

12 ♦ Service procedure

[fil Inspection of engine oil bypass alarm switch Carry out the following inspections and replace the engine oil bypass alarm switch 9 if the results are unsatisfactory: • With no air pressure A applied to engine oil bypass alarm switch 9, check that there is no electrical continuity between the terminal /1 and body 2 of the engine oil bypass alarm switch. • Starting with pressure of O kPa {O kgf/cm2 }, gradually increase the air pressure A on engine oil bypass alarm switch 9. Note the air pressure when electrical continuity appears between the terminal (f. and body , 2 . Verify that this pressure conforms with the specified standard value. 1

11312

B: Air pressure gauge

12-29

LER <Except 6D16-TLE> • Disassembly sequence 1 2 3 4

5 6 7 8 9 10 11

12 13 14

Bypass valve O-ring Oil cooler plug O-ring Nut Oil cooler element O-ring Oil cooler cover Gasket O-ring O-ring Regulator valve P.12-34 Engine oil pressure gauge unit Engine oil pressure switch

*: Crankcase assembly 0 : Non-reusable part

Gr 11

Reverse the order of disassembly.

16779

Service standards Location

Maintenance item

Oil cooler bypass valve opening pressure

Oil cooler element air leakage (air pressure of 980 kPa {10 kgf/cm2} for 15 seconds)

Operating pressure of engine oil pressure switch

Standard value 295 ± 20 kPa {3.0 ± 0.2

kg/cm2 }

0 cc 49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2}

0 Tightening torques Location

Parts to be tightened

Limit

Remedy

Replace Replace

Unit: N · m {kgf · m} Tightening torque

Remarks

Bypass valve

20 ± 4.9 {2.0 ± 0.5}

Oil cooler plug

25 ± 4.9 {2.5 ± 0.5}

Nut (oil cooler element mounting)

20 ± 4.9 {2.0 ± 0.5}

Regulator valve

105 ± 9.8 {11 ± 1}

Engine oil pressure gauge unit

15 to 22 {1.5 to 2.2}

Engine oil pressure switch

15 to 22 {1.5 to 2.2}

12-30

12 p('� Lubricant and/or sealant Points of application

Location

Specified lubricant and/or sealant

2, 4, 11

Apply to O-rings

13, 14

Wrap around thread of engine oil pressure gauge unit and engine oil pressure switch

Quantity

Engine oil

As required

Teflon tape

3 1 /2 turns

-------- ------------�---- ·---�·--- -

♦ Service procedure • Cleaning

• Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 6 and oil cooler cover 8 or in the oil cool er's bypass arrangement. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 6 or oil cooler cover 8. [ L j Gr 14

11] Inspection of oil cooler element Plug outlet A of oil cooler element 6 and connect a hose to the oil inlet. Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

01505

� Engine oil pressure gauge unit 13

�---- --

'•""

If the engine oil pressure gauge unit 13 is installed horizontally, it must be fitted with its arrow pointing upward.

/ 16886

G] Inspection of engine oil pressure switch 2

Perform the following checks, and if any fault is found, replace the engine oil pressure switch 14. • Inspection by not applying air pressure

Make sure that there is continuity between terminals f, and 1

(body).

• Inspection by applying air pressure

• Gradually apply air pressure A to the switch starting from O kPa {O kgf/cm2 }. • Measure the degree of air pressure at the moment when continuity is not detected between terminals 1 and · 2 (body), and make sure to confirm if the value meets the standard. B: Air pressure gauge

12-31

LER <6D16-TLE> • Disassembly sequence 1 Bypass valve plug 2 O-ring 3 Bypass valve spring

4 Bypass valve 5 Engine oil pressure switch 6 Regulator valve CI] P.12-34 7 O-ring 8 Nut 9 Oil cooler element 10 Gasket 11 Oil cooler plug 12 O-ring 13 Oil cooler plug 14 O-ring 15 Oil cooler cover 16 O-ring 17 Gasket *: Crankcase assemb!y

Gr 11

0 : Non-reusable part

®34270

• Assembly sequence Reverse the order of disassembly.

Service standards

Unit: mm

Location 3

Standard value

Limit

Remedy -

84 ± 3N {8.6 ± 0.3 kgf}

Replace

49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2 }

Replace

Maintenance item Bypass valve spring

104.3 ± 1

Free length Spring load (Installed length)

5 9

Operating pressure of engine oil pressure switch

Oil cooler element air leakage (Apply air pressure of 1000 kPa {10.2 kgf/cm2 } for 15 seconds.)

cm3

{0ml}

0 Tightening torques Location

5 6

11 13

Replace

Unit: N · m {kgf · m}

Parts to be tightened

Tightening torque

Remarks -

Bypass valve plug

34.3 ± 4.9 {3.5 ± 0.5}

Engine oil pressure switch

15 to 22 {1.5 to 2.2}

Regulator valve

98 to 118 {10 to 12}

Nut (for fixing oil cooler element)

20 ± 4.9 {2.0 ± 0.5}

Oil cooler plug

25 ± 4.9 {2.5 ± 0.5}

Oil cooler plug

34.5 ± 4.9 {3.5 ± 0.5}

rij Lubricant and/or sealant Location 5 7, 12, 14,16

12-32

Points of application

Specified lubricant and/or sealant

Quantity

T hread of engine oil pressure switch

Teflon tape

Wrap around 3 1 /2 turns

O-rings on oil cooler

Engine oil

As required

12 ♦ Service procedure • Cleaning • Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 9 and in the oil cooler's bypass arrange ment. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 9 or oil cooler cover 15. Gr 14

W Inspection of engine oil pressure switch '.2>

AQ 162021

Perform the following checks, and if any fault is found, replace the engine oil pressure switch 5. • Inspection by not applying air pressure Make sure that there is continuity between terminals 1 and ,2, (body). • Inspection by applying air pressure • Gradually apply air pressure A to the switch starting from O kPa {O kgf/cm2 }. • Measure the degree of air pressure at the moment when continuity is not detected between terminals 1 and 2 (body), and make sure to confirm if the value meets the standard. B: Air pressure gauge � Inspection of oil cooler element

Plug outlet A of oil cooler element 9 and connect a hose to the oil inlet Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure B via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

12-33

LVE • Disassembly sequence 1 Snap ring 2 Valve 3 Spring 4 Body

• Assembly sequence Reverse the order of disassembly. [Installation] [[J P.12-30, 32

2 09189

Service standards Location 3

12-34

Maintenance item Regulator valve spring load (installed length= 48.3 mm) Regulator valve opening pressure

Standard value

(Basic diameter in [ ]) 76 to 80 N {7.8 to 8.2 kgf} 390 ± 29 kPa {4.0 ± 0.3 kgf/cm2}

limit

Remedy

SPECIFICATIONS ........................................ 13A-2 S TRUCTURE AND OPERATION 1. Fuel System ...................... . ....... . ................... . 2. Fuel Filter ...................................................... 3. Secondary Fuel Filter ........................................... 4. Water Separator .. . ............................................. 5. Injection Pump .................................. ,............... 6. Governor ........................... . .................. . ....... 7. Feed Pump . . . . . . ... . ... . . ......................... . . . .... . . . . . 8. Automatic Timer ............................................... 9. B oost Compensator ............................................ 10.lnjection Pump Drive ........................................... 11.lnjection Nozzle ................................................

13A-4 13A-5 13A-5 13A-6 13A-6 13A-9 13A-11 13A-12 13A-14 13A-15 13A-15

TROUBLESHOOTING ..................................... 13A-18 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Checking and Adjusting Injection Timing ........................ 13A-22 2. Checking and Adjusting Minimum and Maximum No- load Speeds . 13A-25 3. Cleaning Fuel Feed Pump Gauze Filter ........................... 13A-26

FUEL FILTER ............................................ 13A-28 SECONDARY FUEL FILTER ............................... 13A-30 WATER SEPARATOR ..................................... 13A-31 INJECTION PUMP <Oldham's Coupling Type> ...... . ................................. 13A-32 <Laminated Coupling Type> 13A-34

INJECTION PUMP DRIVE <Oldham's Coupling Type> ........................................ 13A-40 <Laminated Coupling Type> ............. . .. . .. . ....... . ........... 13A-44

INJECTION NOZZLE <1-spring Type> . . . . ..... . .................. . . ..................... 13A-48 <2-spring Type: BOSCH AUTOMOTIVE SYSTEMS> .................. 13A-52 <2-spring Type: DENSO> . .. . .................. . ................... 13A-62

13A-l

SPE

·-

Injection Pump

"'- �-----

"'-"' Engine model '"' Item

�-----

6015-T

6014-T

6014 STD

STD

OPT

STD

OPT

Bosch A

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanical governor

Feed pump type

Automatic timer type

SA-type mechanical timer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

Model

Governor type

Manufacturer

�-

··--."'- Engine model .....

....

6016-T, 16-PT

6016, 16-E STD

OPT

STD

OPT

Rn�r.h A

Bosch .tJ..

AAcrh 11n

Bc�ch AD

uv.::,1..,111"'\U

RSV-type all-speed mechanir.al grwernm

RFD-type minimummaximum mechanical governor

RSV-type all-speed mechanical governor

RFD-type minimum-maximum mechanicai governor

Feed pump type

Automatic timer type

SA-type mechanical timer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

Item

�,..., .........___...,-........�

Model Governor type

Manufacturer

-�

·------_Engine model

·---�-

n----L-. A r"'I.

SA-type mechanical timer SA-type mechanical timer

BOSCH AUTOMOTIVE SYSTEMS

6D16-TL

BOSCH AUTOMOTIVE SYSTEMS

6D16-TLE

STD

OPT

Bosch AD

Bosch MD

RFD-type minimum-maximum mechanical governor

RSV-type all-speed mechanical governor

RED-IV-type electronic governor

Feed pump type

Automatic timer type

SA-type mechanical timer

SPG mechanical timer

BOSCH AUTOMOTIVE SYSTEMS

Item

Model

Governor type

Manufacturer

JJA-2

------

13 Injection Nozzle ··•. -�":": :o:el

6014

6014-T

6015-T

6D16, 16-E

Hole-type (1-spring)

Item

Model

Hole-type (1-spring)

No. of holes

Hole-type (2-spring)

Hole-type (1-spring)

Hole diameter (mm)

0.28

0.29

0.315

Manufacturer

DENSO

BOSCH AUTOMOTIVE SYSTEMS

DENSO

. -E:gm:-� odel

0.29

0.31

BOSCH AUTOMOTIVE SYSTEMS

0.29

BOSCH AUTOMOTIVE SYSTEMS

6016-T, 16-PT

6D16-TL

6016-TLE

Hole-type (1-spring) I Hole-type (2-spring)

Hole-type (1-spring)

Hole diameter (mm)

0.31

I"\ r")-1

Manufacturer

BOSCH AUTOMOTIVE SYSTEMS

m ~lte:

Model No. of holes

0.2Q

v.v1

0.275

BOSCH AUTOMOTIVE SYSTEMS

Other Items Item Fuel filter type Secondary fuel filter type Water separator type

Specifications Spin-on type (paper filter) Filter paper type Sediment trap type

IJA-3

STRU TURE

1. Fuel System For electronic fuel system, refer to Gr. 13E.

12574

1 Injection nozzle 2 Fuel filter

3 Automatic timer 4 Fuel tank

5 Feed pump

6 Injection pump 7 Overflow valve 8 Governor

• Fuel from the fuel tank 4 is drawn up by the feed pump 5 and strained by the fuel filter 2. The feed pump is driven by a cam in the injection pump 6. • After filtration, fuel is fed to the injection pump 6. From there, it is fed under high pressure to the injection nozzles 1. The injection nozzles spray the fuel into the combustion chambers. • If the fuel pressure in the injection pump 6 exceeds a preset level, the overilow valve 7 opens to allow excess fuel to return to the fuel tank 4.

JJA-4

13 2. Fuel Filter 1 Fuel filter

2 Fuel filter head A: From feed pump B: To injection pump T he fuel filter separates any water content out of fuel fed from the injection pump's feed pump, and its element removes any impurities.

3. Secondary Fuel Filter 1 Secondary fuel filter

2 Air plug 3 Cover 4 Case

5 Element 6 Drain plug 7 Center bolt A: From feed pump B: To fuel filter When the engine is run on JIS class 1 heavy oil (ASTM No. 4; BS class D, B1 and B2), a secondary fuel filter is fitted in the position illustrated. Like the regular fuel filter, this unit separates any water content out of fuel received from the feed pump. It uses a paper element to remove impurities.

18223

13A-5

STRU TURE AN 4. Water Separator

1 Water level ring A. Fuei outiet (to feed pump) B: Fuel inlet

18224

5. Injection Pump

The sediment trap type water separator splits fuel and water centrifugally utilizing the difference in specific gravity between the two fluids. Fuel en tering from the inlet connector is squeezed through a passage in the head, resulting in a faster flow with a more powerful axial twist. Water separated from the fuel settles in the case, and the water-free fuel flows to the feed pump via a passage in the center of the head. The water separator is effective in removing not only water but also dirt and other impurities. A red water level ring 1 floats inside the case, enab ling the water quantity to be checked at a glance.

�: /34 �

6 7

JJA-6

1 Delivery valve holder 2 Delivery valve spring 3 Delivery valve 4

Plunger barrel

5 Control pinion

6 Plunger 7 Control rack 8 Control sleeve 9 Plunger spring 10 Tappet 11 Camshaft The injection pump feeds fuel to the injection nozzles under high pressure and incorporates a mechanism for increasing and de creasing the fuel flow.

13 â&#x20AC;˘ Fuel feed action A: Fuel drawn in B: Start of pressure feed C: End of pressure feed D: Inlet/outlet hole E: Lead

t 1

11 ...__

01824

As the plunger 6 rises and its lead E meets the fuel inlet/outlet hole D, fuel flows through the center of the plunger and is expelled from the inlet/outlet hole. Regardless of how much further the plunger rises, no fuel feed takes place thereafter. The stroke length F of the plunger 6 during which pressure feed takes place is known as the "effective stroke."

01825

â&#x20AC;˘ Injection volume adjustment mechanism To match changes in engine loading, an adjustment mechanism controls the amount of fuel injected. This mechanism turns the plunger 6 by a given angle, thereby altering the point at which the fuel inlet/outlet hole D meets the lead E. Simply stated, the effective stroke is made longer or shorter. A single control rack 7 is used to rotate every plunger in the engine, so the plungers rotate simultaneously and by the same angle.

01826

13A-7

STRUCTURE

N • Delivery valve G: Pressurization starts H: Injection J: Pressurization ends (Starting suction) K: Suction ends L : Suction stroke

K 01827

Fuel highly pressurized by plunger pushes up delivery valve 3 for injec tion, and when delivery of pressurized fuel ends, delivery valve returns by the force of delivery valve spring to close fuel passage, thus avoiding reverse flow of fuel. Delivery valve lowers further to rest at its seat, and for this stroke L, residual pressure between delivery valve and injection nozzle is for an instant lowered. This return suction makes fuel-cutting at nozzles effective and avoids post-injection dripping.

• Overflow valve When the fuel pressure in the injection pump exceeds a preset level, the steel ball R is pushed up, allowing fuel to flow out from the injection pump and return to the fuel tank. This stabilizes the fuel temperature and tem perature distribution in the injection pump and keeps the injection rate constant in each cylinder.

01830

JJA-8

13 6. Governor <RSV Type>

2 \

--ďż˝-- 6

15 -----------

"---9

18225

1 Tension lever

2 Guide lever

3 Supporting lever shaft 4 Governor housing

5 Control rack

6 Adjusting lever 7 Swivel lever

8 Camshaft 9 Flyweight

10 Stop lever 11 Full-load stopper bolt 12 Ungleich spring or idling spring 13 Idling subspring 14 Governor spring 15 Control lever 16 Shackle 17 Start spring

13A-9

STRU TURE ND <RFD Type> 21 \.

::ďż˝

ďż˝'

1 2 3 4 5 6 7

8 9 10 11

Stop lever Governor housing Governor spring Control rack Swivel lever Camshaft Speed control lever Flyweight Sliding lever Sleeve Floating lever

JJA-10

9 18227

12 13 14 15 16 17

18 19 20 21

Stroke adjusting bolt Idling spring Torque spring Smoke set assembly Damper spring Start spring Floating lever link Tension lever Guide lever Governor cover

13 7. Feed Pump 1 Priming pump

2 Inlet check valve

3 Gauze filter

4 Outlet check valve 5 Feed pump housing A: From fuel tank B: To fuel filter The feed pump is driven by the camshaft in the injection pump. The priming pump 1 enables fuel to be drawn up manually when the injection pump is stationary. It is particularly useful for air bleeding. The gauze filter 3 removes large impurities from fuel drawn up from the fuel tank and thus prevents clogging of the feed pump. It must be washed regularly in gas oil.

14431

• Suction stroke When the injection pump camshaft 6 forces up the push rod 7, fuel in the suction chamber C is compressed and opens the outlet check valve 4. Most of the fuel forced out is drawn into the pressure chamber D below the piston.

13912

• Pressure feed stroke

As the camshaft 6 turns and the cam loses its lift, the piston 9 is pushed down by the piston spring 8. The fuel in the pressure chamber D is thus forced out and fed toward the fuel filter. At the same time, the outlet check valve 4 closes and the inlet check valve 2 opens. As a result, fuel is again drawn into the suction chamber C.

13913

• Stoppage When pressure in the pressure chamber D exceeds a preset level, the pis ton spring 8 cannot push back the piston 9. The pump therefore stops op erating, preventing pressure in the fuel filter from rising more than neces sary.

13914

13A-ll

STRUCTURE

8. Automatic Timer The automatic timer utilizes a mechanical arrangement to adjust the injection timing in accordance with the engine speed. The automatic timer is mounted on the injection pump camshaft using a round nut. Via a driving disk, it is driven by the air compressor crankshaft or pump drive shaft. <SA-type automatic timer>

18228

1 Timer housing

5 Spring seat

2 Flyweight 3 Roller

6 Shim

7 Flange 8 Cover

4 Timer spring

• With engine stationary

When the engine is stationary, the timer spring 4 overcomes the centrifu gal force acting on the flyweight 2. The flyweight roller is therefore held down by the flange 7, and the injection timing arrangement is not ad vanced.

• With engine running

As the engine speed rises, the centrifugal force on the flyweight 2 in creases. With the timer housing pin A as the fulcrum, the flyweight roller 3 thus moves outward while pushing the curved surface of the flange 7, causing the flange to compress the timer springs 4. As a result, the roller 3 of the flyweight 2 moves the flange 7 in the rotating directing and the in jection timing is advanced.

18230

13A-12

13 <SPG-type automatic timer> 1 Timer housing 2 Eccentric cam (small) 3 Eccentric cam (large) 4 Timer holder 5 Flyweight 6 Timer spring 7 Pilot pin 8 Cover

• With engine stationary With the engine stationary, flyweight 5 is held against timer holder 4 by the force of timer spring 6.

• With engine running

Retardation angle

®47185

As the engine speed increases, the centrifugal force exerted on flyweight 5 matches the force of timer spring 6. As the engine speed increases fur ther, the centrifugal force overcomes the force of spring, causing the fly weight to move outwards. As the flyweight moves outwards, eccentric cam (small) 2 rotates in the reverse direction of the shaft rotation about pin A of the timer housing. Also, center B of eccentric cam (large) 3 rotates in the reverse direction of the shaft rotation about center C of the timer. The eccentric cam (large) has been fit into timer holder 4. Therefore, the movement of the eccentric cam (large) is transmitted to the timer holder. The maximum retard is achieved when the back of the flyweight bottoms against the inner surface of timer housing 1.

13A-13

STRU TURE AND 9. Boost Compensator

1 --3

10 P47186

1 Inlet manifold

2 Turbo charger 3 Turbine

4 Boost compensator spring

5 Boost compensator 6 Hose

Diaphragm Push rod Compensator lever Governor 11 Floating lever 12 Control rod 7 8 9 10

A: Boost pressure

B: C: D: E, F:

Intake air Exhaust More fuel Pivot

• The boost compensator is designed to ensure that a greater amount of fuel is injected as the turbo charger feeds more air into the engine so that the engine output increases accordingly. • As boost pressure A in inlet manifold 1 overcomes the force of boost compensator spring 4 of boost compensator 5, dia phragm 7 and push rod 8 are pushed to the left. • As push rod 8 is pushed to the left, compensator lever 9 moves counterclockwise about pivot F to the position shown by the dotted line. This causes floating lever 11 to move counterclockwise about pivot E, which in turn moves control rod 12 in the direction of D (more fuel). As a result, a greater amount of fuel is injected irrespective of the operations of gover nor 10.

13A-14

13 1 O. Injection Pump Drive 1 Pump drive case

2 Bearing 3 Pump drive gear 4 Pump drive shaft 5 Coupling

A: Timing gear side B: Timer side

The injection pump drive is fitted onto the flywheel housing on the left of the engine. It is driven by the engine timing gear at half the engine speed. The pump drive shaft 4 drives the injection pump via the couÂ pling 5 on its timer side.

11. Injection Nozzle <1-spring type> 1 Nozzle spring 2 Needle valve

3 Nozzle 4 Adjusting screw 5 Nozzle holder

ďż˝B

A: To leak-off pipe

B: From injection pump

Fuel fed from the injection pump enters the nozzle holder 5. When the fuel pressure in the nozzle holder exceeds a preset pressure, it overcomes the nozzle spring 1, pushes up the needle valve 2, and the fuel is sprayed into the cylinder from the orifice at the end of the nozzle 3. Some of the high-pressure fuel lubricates the needle valve 2 and returns to the fuel tank via the leak-off pipe.

04538

13A-15

STRU TURE <2-spring type>

1 Valve opening pressure adjustment shim 2 Prelift adjustment shim

3 1st spring

4 1st push rod

5 Nozzle 6 Needle valve 7 Nozzle holder 8 2nd push rod 9 2nd spring

9 8

Inside the nozzle, there are two springs 3, 9 and two push rods 4, 8. A prelift clearance is provided between the two push rods.

----

---

--18361

<DENSO>

�B

9 ____

18362

JJA-16

When high-pressure fuel from the injection pump overcomes the 1st spring 3 (this spring determines the valve opening pres sure), the needle valve 6 pushes up the 1st push rod 4, thereby opening the valve. When the 1st push rod 4 moves through the prelift clearance and contacts the 2nd push rod 8, the needle valve 6 momentari ly stops lifting As thA f1 JAi prAc:c:, irA inrn::i�c:Ac: f11rthAr �nrl f"\uorcomes the combined force of the 1st spring 3 and 2nd spring 9, the needle valve 6 lifts again for the main injection.

13A-17

TR UBLESH Symptoms

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Possible causes Injection pump proper

Worn tappet

0 0 0 0

'vVom camshaft

Sticky plunger Sticky control rack Sticky delivery valve

Worn plunger Defective delivery valve seat Insufficient plunger slide stroke Broken plunger spring

Defective sliding action in control rack Tappet worn or not sliding correctly Broken delivery valve spring Poor airtightness due to loose delivery valve holder Defective delivery valve operation Loose control pinion Plunger spring not seating correctly Delivery valve holder too tight

Uneven injection volume to cylinders Check valve not operating Sticky piston Sticky push rod Worn tappet Defective check valve operation Piston worn

JJA-18

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Excessively advanced injection timing

Gauze filter clogged

(]) C

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0 0 0 0

Poorly adjusted injection timing

Fuel feed pump

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I 13A I Symptoms

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Possible causes Governor

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0 0 U)

Weak governor spring Incorrectly adjusted control lever

0..

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Excessive friction or play in links Loose round nut Poorly adjusted idling set bolt

w w w

I(I)

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0 0 0 0 0

Valve opening pressure too low Blocked injection orifice Poor airtightness in nozzle

0 0 0

Valve opening pressure too high Broken spring

()

Defective sliding action in needle valve

0 0

Defective valve opening pressure

0 0

0 0 0

()

r-,

Weakness/deterioration in spring Fuel filter

I...

1ti

(/)

ID .2

Stop mechanism damaged Sticky needle valve

0..

0 0

Defective sliding action in control lever

Injection nozzles

0.. :::,

0 0 0 0 0

Bent links

Defective advancing action

co "O

Flyweights not operating effectively Weak idling spring

Automatic timer

·o, ·o, ·o, ID u C C C u C

0 0 0 0

Insufficient full-load stopper position

0 C

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Filter (and/or secondary filter) clogged

()

0 0 0

Fuel tank empty Fuel pipes blocked and/or fuel leaking from connections Air or water in fuel system Low-quality fuel in use

()

(�)

()

Cracked fuel pipe

(' ,,)

0 0 0 0 0

Leaky fuel tank Incorrect oil viscosity

Gr. 12

Incorrect valve clearance

Gr. 11

()

Defective head gasket

Gr. 11

Wear and/or carbon deposits on valve and valve seat

Gr. 11

()

Weakness/deterioration in valve spring

Gr. 11

()

13A-19

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Engine will not start

0 0 0 0 0 0 Engine difficult to start Engine knocks Unstable engine output insufficient engine output Engine maximum speed too high 0

0 0 Unstable engine idling Engine stops soon after starting Engine does not reach maximum speed Engine will not stop Accelerator pedal too stiff Defective fuel supply

ENT

N-VEHI LE INSPE 1. Checking and Adjusting Injection Timing <Except 6D16-TLE> Service standards

0 Tightening torques

Unit: N · m {kgf · m} Tightening torque

Parts to be tightened

Location

25 {2.5}

Union nut (injection pipe mounting)

Bolt (delivery valve DENSO holder lock plate) BOSCH AUTOMOTIVE SYSTEMS <A-type> BOSCH AUTOMOTIVE SYSTEMS <AD-type>

Delivery valve holder

7.8to11 {0.Btoi.1} 4.4 to 6.0 {0.45 to0.6}

Remarks

3.4 to4.9 {0.35 to0.5}

DENSO

34 to39 {3.5 to4}

BOSCH AUTOMOTIVE SYSTEMS <A-type>

39 to44 { 4 to4.5}

BOSCH AUTOMOTIVE SYSTEMS <AD-type>

49 to54 { 5 to5.5}

[Inspection] • From the injection pump's No. 1 cylinder, remove the injection pipe 1, lock plate 2, delivery valve holder 3, stopper 4, delivery valve spring 5, and delivery valve 6. • Fit the delivery valve holder 3.

CAUTION&_------------ Place all parts in gas oil after removal to keep them free of dust.

18934

• Fit an injection pipe 7 onto cylinder No. 1. Point the pipe's other end downward such that fuel flowing out can be seen clearly. • Rotate the crankshaft pulley clockwise (as seen from the front of engine) by at least 180 ° and bring cylinder No. 1 to approximately 30 ° BTDC on its compression stroke.

NOTE

18935 7

If the engine is turned in its reverse direction (when stopping the engine or by cranking), the automatic timer may stay in an ad vanced condition. This may not be cancelled by a slight forward rotation of the engine. Be sure to crank the engine forward manu ally by at least 180 ° .

• Feed fuel into the injection pump using the priming pump 8. With fuel flowing out of the injection pipe 7, crank the engine slowly clockwise (as seen from the front of engine).

NOTE

Ensure that the stop lever 9 at the side of the governor is not in its STOP position.

18936

13A-22

13 • When the flow of fuel from the injection pipe 7 diminishes, crank the en gine more slowly. When the flow of fuel stops completely, stop cranking the engine.

18937

• Check that the pointer 10 on the flywheel housing or torsional damper B indicates the value 1 ° earlier than the correct fuel injection timing.

A: Flywheel

NOTE

14814

14584

• The injection timing in this measurement becomes 1 ° earlier than the correct injection timing due to the inactivation of the delivery valve spring. • The correct injection timinQ is indicated on the plate attached on the rocker cover. • If the injection timing should be measured in a dusty location, perform as follows: • Rotate the crankshaft pulley clockwise (as seen from the front of engine) and bring the No. 1 cylinder to 30 ° BTDC on its compression stroke. • Disconnect the injection pipe 1 with a little amount of fuel remained at the top of the delivery valve holder 3. • Slowly rotate the crankshaft pulley clockwise. When the injection timing is reached, the fuel at the top of the delivery valve holder 3 starts to move. • If the injection timing is out of the specification, adjust as follows: [Adjustment] • Loosen the nuts 12 that hold the timer case 11 onto the pump drive or air compressor 13. • If the fuel injection timing is overly retarded, incline the injection pump toward the crankcase. • If the fuel injection timing is overly advanced, incline the injection pump away from the crankcase.

NOTE 11

01852

Turning the injection pump by one of the gradations inscribed on the timer case flange C causes a 6° change in the injection timing.

• Tighten the nuts 12, then check the fuel injection timing again.

NOTE

If the fuel injection timing is so far out of specification that adjust ment with the injection pump is not possible, the engine timing gear and injection pump drive gear may not be meshing correctly. If this occurs, remove and refit the air compressor or injection pump drive. • Air compressor: Gr. 61 P.13A-40 • Injection pump drive: • After checking that the fuel injection timing is up to specification, fit the delivery valve 6, delivery valve spring 5, and stopper 4.

l JA-23

N AND ADJUST ENT

N-VEHI LE INSPE

• Tighten each part to its specified torque.

01853

<6D16-TLE> Service standards

0 Tightening torques

Unit: N · m {kgf · m}

[Inspection] • Turn the crankshaft by 180 ° or more in the forward direction to bring cylinder No. 1 to TDC on its compression stroke. Set the injection tim ing by aligning the specified value shown on scate A stamped on the periphery of the flywheel with pointer 1 on the flywheel housing.

CAUTION

If the engine is turned in reverse while the engine is stationary, the automatic timer can move to an advanced position. To return the automatic timer to a normal position, it may be necessary to manually rotate the engine forward by 180 ° or more.

• The injection timing is correct if line B inscribed in the injection pump aligns with line C inscribed in the automatic timer. • If out of alignment, adjust using the following procedures.

P46823

[Adjustment] • Loosen adjusting bolt 2. Turn the automatic timer to align line B with line C. • Tighten adjusting bolt 2 to the specified torque. • Repeat the injection timing inspection.

CAUTION&------------ 2 P47366

13A-24

Only adjusting bolt 2 should be loosened.

13 2. Checking and Adjusting Minimum and Maximum No-load Speeds Service standards Maintenance item

Location

Standard value

No-load minimum speed

No-load maximum speed

Remedy

Depends on specifications

Limit -

Depends on specifications

Adjust

Start the engine and allow it to warm up before carrying out the following inspections. <RSV-type governor>

• No-load minimum speed

[Inspection] Confirm that the control lever 1 is touching the idling set bolt 3. Then check that the minimum speed is up to specification.

A: Idling position

18231 I

[Adjustment] If the rninirn1_1rn speed is ni_1t nf sper.ifir.8tion, adjust it using the idling set bolt 3. • No-load maximum speed

<RFD-type governor> A,�-...--

[Inspection] Confirm that the control lever 1 is touching the full-speed set bolt 2. Then, check that the maximum speed is up to specification.

B: Full-speed position

18232

[Adjustment] If the maximum speed is out of specification, adjust it using the full-speed set bolt 2.

NOTE

Check that the engine does not stall and that no hunting occurs when the control lever 1 is moved quickly from the full-speed position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

9 6

• No-load minimum speed [Inspection] Confirm that the load control lever 7 is touching the idling set bolt 6. Then check that the minimum speed is up to specification. A: Idling position

A 11

18233

[Adjustment] If the minimum speed is out of specification, adjust it using the idling set bolt 6.

JJA-25

N-VEHICLE INSPECTI N AND DJUST ENT • No-load maximum speed [Inspection] Move the load control lever 7 to the full-load position B. Then, check that

the maximum speed is up to specification. [Adjustment]

If the maximum speed is out of specification, adjust position of the speed control lever 8 using the maximum speed stopper bolt 9 and stopper bolt 10.

NOTE

• Do not alter the position of the full-load stopper bolt 11. • Check that the engine does not stall and that no hunting occurs when the load control lever 7 is moved quickly from the full-load position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

3. Cleaning Fuel Feed Pump Gauze Filter 0 Tightening torques Location 1

Unit: N · m {kgf · m} Remarks

BOSCH AUTOMOTIVE SYSTEMS DENSO

• Remove the eyebolt 1 from the suction port side of the fuel feed pump. • Remove the gauze filter 2 from the eyebolt 1.

• Clean the gauze filter 2. • Refit the gauze filter 2 and eyebolt 1 in the opposite order to their re moval. • Bleed all air out of the fuel system. • Start the engine and check for fuel leaks.

13A-26

13A-27

FUEL Fl

ER <Type B>

111-----30

za 2

®47190

®47191

5-�

®47193

®47192

• Disassembly sequence 4 Fuel filter 5 Fuel filter head

1 Eyebolt 2 Fuel pipe 3 Air vent plug • Assembly sequence Reverse the order of disassembly.

0 Tightening torques Location

� Lubricant

13A-28

Parts

Unit: N · m {kgf · m} Remarks

13 � Special tools Tool name and shape

Location

Part No.

Application

Filter Wrench

Part No.

Filter model

MH061509

90.2

A,B

MH061572

94.2

C,D

MH061509 MH061572

Removing fuel filter

♦ Service procedure

[I] Fuel filter [Removal]

WARNING.&------------• Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spiiieci iuei.

01883

[Installation]

WARNING.&------------ Use of an unsuitable fuel filter 4 can lead to fuel leaks and fires. Be sure to use a genuine Mitsubishi filter.

13220

• To fit the fuel filter 4, turn it until the gasket C touches surface B of the fuel filter head 5. T hen, tighten the filter by 3/4 to 1 turn. Be sure to turn the filter by hand. "' Start the engine and check for fuel leaks.

JJA-29

NDARY FUEL FILTER • Disassembly sequence

i--2

r''

1 Eyebolt 2 Air vent plug 3 Drain plug 4 Center bolt 5 Case 6 Spring 7 Element 8 O-ring 9 Fuel filter head

80 7 ..-6

0 : Non-reusable part • Assembly sequence Reverse the order of disassembly.

182371

0 Tightening torques Location

13A-30

Unit: N · m {kgf · m} Remarks

ER SEPAR

R • Disassembly sequence 1 Eyebolt

2 Air vent plug 3 0-ring

4 Drain plug 5 Ring nut 6 Case 7 Isolation plate 8 Screen assembly 9 Baffle plate 10 Water level ring 11 Head 12 O-ring 0: Non-reusable part

WARNING_&----------• Fuel ignites easily. Do not get it near flame or heat. • Wipe up any spilled gas oil because it can cause a fire.

203051

• Assembly sequence Reverse the order of disassembly.

0 Tightening torques Parts to be tightened

Location

Unit: N · m {kgf · m} Tightening torque

Remarks

Eyebolt

Air vent plug

7.8 to i 2 {0.8 to 1.2}

Drain plug

2.9 to 3.9 {0.3 to 0.4}

Ring nut

5.9 to 7.8 {0.6 to 0.8}

34 {3.5}

13A-3 l

ldham's Coupling

INJECTI

pe>

@)� 12

®18238

• Disassembly sequence 1 2 3 4 5 6 7 8

Eyebolt Fuel feed hose Eyebolt Fuel suction pipe Eyebolt Fuel feed hose Eyebolt Fuel return pipe

9 10 11 12 13 14 15

Injection pipe Eyebolt Eyebolt Connector Oil pipe Injection pump stay Injection pump assembly

16 Driving disk 17 O-ring

*: Injection pump drive

P.13A-40, or air compressor [I] Gr. 61 0: Non-reusable part

• Assembly sequence Reverse the order of disassembly.

WARNING.&------------------------ • Fuel is highly flammable; keep it away from flames and sources of heat. � To minimize the risk of fire, wipe up any spilled fuel. CAUTION_&------------------------- Dirt particles in the injection pump assembly 15 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal. NOTE For maintenance of the injection pump assembly 15, please contact a BOSCH AUTOMOTIVE SYSTEMS service station or DENSO service station.

l 3A-32

13 0 Tightening torques Location 1, 7

3,5

Unit: N · m {kgf · m} Tightening torque

Parts to be tightened Eyebolt (fuel feed hose, fuel return pipe)

Eyebolt (fuel suction pipe, fuel feed hose)

BOSCH AUTOMUflVt: ::>Y::>TEMS

20 to 29{2 to 3}

DENSO

15 to 20 {i .5 to 2}

BOSCH AUTOMOTIVE SYSTEMS

20 to 25{2 to 2.5}

DENSO

15 to 20{1.5 to 2}

Injection pipe union nut

25{2.5}

Eyebolt (oil pipe; air compressor or pump drive side)

21{2.1}

Eyebolt (oil pipe; injection pump side)

BOSCH AUTOMOTIVE SYSTEMS DENSO

10 to 13{1 to 1.3}

7.8 to 13 {0.8 to 1.3} 21{2.1}

Connecter (oil pipe)

Remarks -

♦ Service procedure (I§] Installing injection pump assembly • Bring cylinder No. 1 of the engine to the TDC position of its compres sion stroke.

• Align the inscribed lines C on the timer case A and timer B. Then, fit the injection pump assembly 15 onto the air compressor or injection pump drive.

B 01886

13A-33

13 • Disassembly sequence 1 Eye bolt

2 Fuel feed hose

3 4 5 6 7 8 9

11 12 13 14 15 16

Eye bolt Fuel suction pipe Eye bolt Fuel feed hose Eye bolt Fuel return pipe Injection pipe Eye bolt Eye bolt Eye bolt Oil pipe Eye bolt Oil return pipe Eye bolt (mechanical governor)

17 18 19 20 21

23 24 25 26

Boost hose (mechanical governor) Eye bolt (mechanical governor) Oil pipe (mechanical governor) Bolt Cotter bolt Driving coupling Injection pump assembly Bolt Injection pump bracket Key

*a: Injection pump drive Gr. 61 *b: Engine speed sensor 0: Non-reusable part

P.13A-44 or air compressor Gr. 13E

• Assembly sequence Reverse the order of disassembly.

CAUTION&,--------------------------

• Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel. • For maintenance of the injection pump assembly 23, please contact a Bosch Automotive Systems service sta tion or Denso service station. • Dirt particles in the injection pump assembly 23 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal. • Never carry around the injection pump assembly 23 by holding it at the lever or the engine speed sensor *b. Removing the lever may result in deteriorated pump performance. • Do not remove the injection pump bracket 25 unless it is faulty.

13A-35

P <Laminated

INJE

oupling

pe>

Service standards

Unit: mm

Standard value

Maintenance item

Location

Depends on specifications

Fuel injection timing (BTDC) Injection pump bracket (eccentricity between injection pump centering tool and injection pump drive or air compressor crankshaft)

0.2

0 Tightening torques

Limit -

Remedy Adjust

Adjust

Unit: N · m {kgf · m}

1, 7

Eye bolt (for fitting fuel feed hose and fuel return pipe)

20 to 29 {2 to 3}

Remarks -

3, 5

Eye bolt (for fitting fuel suction pipe and fuel feed hose)

20 to 25 {2 to 2.5}

Tightening torque

Parts to be tightened

Location

25 {2.5}

Injection pipe (for fitting union nut)

Eye bolt (for fitting oil pipe on either injection pump drive or air compressor side)

20.6 {2.1}

Eye bolt (for fitting oil pipe on injection pump side)

10 to 13 {1 to 1.3}

Fye b0lt {for fitting o!! p!pe Or! cra!:kcase side)

Eye bolt (for fitting oil return pipe)

16 19 20 21

Eye bolt (for fitting boost hose)

r')r\ C fr') -11

C-V,U l"-· If

Mechanical governor Electronic governor

20 to 25 {2 to 2.5} 20 to 29 {2 to 3}

10 to 13 {1 to 1.3} 25 {2.6}

Oil pipe

59 to 64 {6 to 6.5}

Bolt (for fitting driving coupling) Cotter bolt

83 to 93 {8.5 to 9.5}

(&] Special tools Location

Tool name and shape

Part No.

Injection Pump Centering Tool

MH063393

Application

Locating injection pump bracket

®13221

♦

Service procedure

� Installing injection pump assembly • Crank the engine to set cylinder No. 1 at the specified injection timing position.

13A-36

13 *a

• Ensure that the key way A on the injection pump drive or air compres sor (*a) crankshaft is facing upwards. • If key way A is not facing upwards, rotate the engine crankshaft by one turn.

13222

• Align line B inscribed on the injection pump and line C inscribed on the automatic timer.

¥ -�®4682� I *a

• Fit driving coupling 22 to the injection pump drive or air compressor *a crankshaft D. Push the driving coupling against the injection pump drive or air compressor crankshaft D. • Fit injection pump assembly 23 to injection pump bracket 25.

13223

• Set driving coupling 22 apart from coupling plate Eby 0.5 mm as shown in the illustration. Tighten cotter bolt 21 to the specified torque.

13185

• Using bolts 20, fit driving coupling 22 and coupling plate E.

13A-37

P <Laminated Coupling

INJE

pe>

� Injection pump bracket

(Inspection] • Set dial gauge Bat rod A of� Injection Pump Centering Tool for zero pui11t (.;UI r t:diur 1.

• Slide dial gauge Bagainst the injection pump drive or the air compres sor *a and measure the eccentricity between rod A and the crankshaft C of the injection pump drive or the air compressor at D, E and F. • If one of the measurements exceeds the specified value, adjust as fol lows.

-----*a C

132251

[Adjustment] • When the measured value at point E is higher than the standard value: Insert shims G into four points equally. • When the measured value at point Dis higher than the standard value: Insert shims G into lower side H. • When the measured value at point Fis higher than the standard value: Insert shims G into upper side J.

CAUTION&,--------------

lnsert shims G observing the following conditions: • Number of shims per point is three or less. • The same number of shims should be used for the front and the rear. • The difference in number of shims used for bottom and top is none or one. • Tighten bolts 24 to the specified torque and repeat the inspection.

JJA-38

13A-39

P DRIVE < ldham's Coupling

INJE

pe>

• Disassembly sequence

1 Injection pump drive assembly 2 Nut 'l V

4 5 6 7 8 9

"--

160

11 12 13 14 15 16

Lock washer Drive gear Collar Bolt Pin Coupling Bolt Cover Bolt Bearing Bearing holder Shaft Pump drive case O-ring

*a: Injection pump assembly [Ci P.13A-32

• Assembly sequence Reverse the order of disassembly.

®47199

Service standards

Unit: mm Limit

Remedy

Shaft end play

0.59

Replace

Shaft-to-pump drive case clearance

0.12

Replace pump drive case

Location

14 14,15

Maintenance item

Standard value

0 Tightening torques Location

Parts to be tightened Eyebolt

Unit: N · m {kgf · m} Tightening torque

2 5to2 {2.5 9 to 3}

5.9 to 6 .{ 9 . 0 6 to 0.75}

21{2.1 }

Nut (drive gear mounting)

1 7 6 to211{17to21. 5}

Bolt (coupling mounting)

30 to 36{3.1 to 3.7}

Bolt (cover mounting)

Bolt (bearing holder mounting)

13A-40

Remarks

13 p(\ Lubricant

♦ Service procedure

IT] Installing injection pump drive assembly • Bring cylinder No. 1 of the engine to the TDC position of its compres sion stroke. [I] Gr. 11 • Align the inscribed line A on the drive gear 4 of the injection pump drive assembly 1 with the inscribed line A on the pump drive case 15.

Oi919

• Remove the plug C from the flywheel housing B, then check that the inscribed line A on the dnve gear 4 1s a11gned with the pointer D. if the line and pointer are not aligned, remove and refit the injection pump drive assembly.

� Installing drive gear • Fit the drive gear 4 such that its "O" alignment mark is aligned with the "O" alignment mark on the shaft 14. Then, fit the lock washer 3 such that its notch A is aligned with the drive gear alignment mark, and tighten the nut 2 to the specified torque.

• When the assembly is complete, bend the lock washer 3 down onto the nut 2.

3 P46828

13A-41

P DRIVE

INJE

ldham's Coupling

pe>

ďż˝ ďż˝ Shaft-to-pump drive case clearance C

If the clearance exceeds the specified limit, replace the pump drive case 15. A: Bushing B: Measurement directions C: Measurement positions

14 01923

021m 1

JJA-42

EMO

13A-43

INJECTI

P DRIVE <Laminated

oupling

pe>

• Disassembly sequence 1 Injection pump drive assembly

2 Nut 3 Lock washer 4 Drive gear 5 Collar 6 Bolt 7 Oil seal 8 Bearing holder 9 O-ring 10 Sleeve 11 Bearing 12 Shaft 13 Pump drive case 14 O-ring *a: Injection pump assembly [fl P.13A-34 *b: Oil pipe P.13A-34

Reverse the order of disassembly.

Service standards

0 Tightening torques

� Lubricant

13A-44

Unit: mm

Unit: N · m {kgf · m}

13 ♦ Service procedure

OJ Installing injection pump drive assembly • Set cylinder No. 1 of the engine at TDC on the compression stroke. Gr. 11 • Align line A inscribed on drive gear 4 of injection pump drive assembly 1 with line A inscribed on pump drive case 13.

®46825

• Remove plug C from flywheel housing B. Check if line A inscribed on drive gear 4 is aligned with pointer D. If not, remove and refit injection pump drive assembly 1 to obtain the alignment.

[!] Installing drive gear • Install drive gear 4 such that its "O" alignment mark is aligned with the "O" alignment mark on shaft 12. • Fit lock washer 3 such that its notch A is aligned with the "O" alignment mark on drive gear 4. Tighten nut 2 to the specified torque.

• After the drive gear is installed, bend lock washer 3 over nut 2. 2

3 P46828

13A-45

P DRIVE <Laminated Coupling

pe>

[I) Installing oil seal Face oil seal 7 as shown in the illustration. Then, fit it in bearing holder 8 by pressing evenly until it is flush with the end face A of the holder.

ÂŽ46829

JJA-46

JJA-47

INJE

ZZLE <1-spring

pe> • Pre-disassembly Inspection 11 J P.13A-49

e Disassembly sequence 1 Eyebolt 2 Fuel leak-off pipe 3 Injection pipe 4 Bolt 5 Injection nozzle assembly 6 Connector 7 Cap nut 8 Adjusting screw 9 Spring 10 Push rod 11 Retaining nut 12 Nozzle 13 Needle valve 14 Pin 15 Nozzle holder i6 Dust seai 17 Gasket 0: Non-reusable part Repair kit : Nozzle Service Kit (for BOSCH SYSTEMS AUTOMOTIVE nozzles only) • Assembly sequence Reverse the order of disassembly. 04555

WARNING.Lt_------------------------ To minimize the risk of fire, wipe up any spilled fuel.

CAUTION.Lt_-------------------------

Under no circumstances change the needle valve 13 and nozzle 12 combination used in each injection nozzle assembly 5.

NOTE

• Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly. • When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

1 JA-48

13 Service standards

Unit: mm

0 Tightening torques Location 1

Unit: N · m {kgf · m} Tightening torque

Parts to be tightened Eyebolt (fuel leak-off pipe mounting)

Injection pipe union nut

Bolt (injection nozzle mount ing)

BOSCH AUTOMOTIVE SYS TEMS

9.8 to 15 {1.0 to 1.5}

DENSO

15 to 20 {1.5 to 2.0} 25 {2.5}

BOSCH AUTO MOTIVE SYS TEMS

Connector

15{1.5} 12 to 14 {1.2 to 1.4}

DENSO 6

Remarks

BOSCH AUTO MOTIVE SYS-

69 to 78 {7 to 8}

� Special tools

Unit mm

* BOSCH AUTOMOTIVE SYSTEMS part number

♦ Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for in spection.

NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement. (1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the adjusting screw 8. • If the measurement is still out of specification after adjustment, re place the injection nozzle assembly 5. 01910

WARNING&_-----------Do not touch the spray that comes out of the nozzle.

JJA-49

ZZLE <1-spring

INJECTI Good �

(2) Inspecting spray condition

Bad

!j t

Iii

pe>

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke, and maintain a continuous spray.

B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) D: Asymmetrical spray (Bad) E: Branched spray (Bad) F: T hin spray (Bad) G: Irregular spray (Bad)

06931

• If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING&-----------Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm2 } below the specified valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 still appears defective, it must be replaced. Good

Bad

05388

[§] A

Injection nozzle assembly

[Disassembly]

CAUTION&-------------• Do not touch the sliding parts A of the needle valve 7. • Do not change the needle valve 13 and nozzle 12 combination on each cylinder.

04744

[Cleaning] Wash the needle valve 13 and nozzle 12 in gas oil, then use the� Clean ing Tool Set to remove any carbon deposits in accordance with the follow ing procedure. • Remove carbon from the end of the needle valve 13 using the Cleaning Bar of the � Cleaning Tool Set.

CAUTION&-------------Do not use a wire brush or any hard metallic object for cleaning. 04556

JJA-50

13 • Remove carbon from the injection orifice of the nozzle 12 using the Needle Cleaner of the� Cleaning Tool Set. Insert the Needle Cleaner and rotate it to dislodge the carbon.

�

• Clean the seat of the nozzle 12 using the Cleaning Scraper of the � Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

018941

01911

[Inspection] • Wash the needle valve 13 and nozzle 12 in gas oil, then fit them togeth er. • Pull up the needle valve 13 by approximately 1 /3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 13 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 12 as a set.

NOTE

Whenever a nozzle 12 is replaced, the nozzle and needle valve 13 must be replaced as a set using Nozzle Service Kit. (This applies to BOSCH AUTOMOTIVE SYSTEMS products only.)

13A-51

INJECTION NO

· BOSCH AUTOMOTIVE SYSTEMS>

LE <2-spring

• Pre-disassembly inspection P.13A-54

e Disassembly sequence 1 2 3 4 5 6 7

8 9 10

21 20

�

12 13 14

19----19 18�

iS 16 17

18 19 20 21 22 23 24 18239

Eyebolt Fuel leak-off pipe Injection pipe Bolt Injection nozzle assembly Cap nut Adjusting screw Lock nut 2nd spring Set screw 2nd push rod Shim (for adjusting prelift) Spacer Shim (for adjusting valve opening pressure) 1st spnng 1st push rod Retaining nut Nozzle Needle valve Pin Nozzle holder Nozzle holder joint Dust seal Gasket

0 : Non-reusable part • Assembly sequence Reverse the order of disassembly.

WARNING

To minimize the risk of fire, wipe up any spilled fuel.

CAUTION_&-------------------------

Under no circumstances change the needle valve 19 and nozzle 18 combination used in each injection nozzle assembly 5.

NOTE

JJA-52

13 Service standards Standard value

Maintenance item

Location 5

Unit: mm

Injection pressure

1st valve opening pressure

16.7

+g.49

2nd valve opening pressure (cover pressure)

21.6

+g.49

MPa {170

kgf/cm2 }

MPa {220

+�

kgf/cm 2 }

Remedy Adjust

Adjust

0.08

Prelift

0 Tightening torques

Unit: N · m {kgf · m} Remarks

Tightening torque

Parts to be tightened

Location

Limit

9.8 to 15{1.0 to 1.5}

Injection pipe union nut

25{2.5}

Bolt (injection nozzle mounting)

15{1.5}

Cap nut

39 to 49{4 to 5}

Lock nut

20 to 25 {2 to 2.5}

Set screw

49 to 59{5 to 6}

Retaining nut

59 to 79{6 to 8}

Nozzle holder joint

69 to 79{7 to 8}

Eyebolt (fuel leak-off pipe mounting)

� Special tools

Unit: mm

Nozzle Cleaning Tool Adjusting Device *Retaining Nut (for adjustment) *Gasket * Adjusting Device 5

Part No.

Tool name and shape

Location

*Dial Gauge *Base *Pin (f = 60.5 mm) *Connector *Pin (f 50 mm) *Gasket

* BOSCH AUTOMOTIVE SYSTEMS product number * Component of Adjusting Device (105789-0500)

�a *105785-1010

Application Cleaning injection nozzle assemblies

*105789-0500

�b *157892-1420 �c *157892-1500 �d *157892-0220

�e ,\-157954-3800 �f

*157892-1800

�g *157892-1100 �h *157892-1320 �j *157892-1200 �k *026508-1140

13A-53

LE <2-spring

INJECTION N

: BOSCH AU

M TIVE SY

EMS>

♦ Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for in spection.

NOTE

Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement.

(1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the shims 12, 14. • If the measurement is still out of specification after adjustment, re place the injection nozzle assembly 5.

WARNING,&-----------Do not touch the spray that comes out of the nozzle. (2) Inspecting spray condition

Bad

�

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke, and maintain a continuous spray.

06931

B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) D: Asymmetrical spray (Bad) E: Branched spray (Bad) F: Thin spray (Bad) G: Irregular spray (Bad) • If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING&_-----------Do not touch the spray that comes out of the nozzle. (3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm2 } below the specified 1st valve opening pressure. Maintain this pressure for 1O seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 still appears defective, it must be replaced. Good

13A-54

Bad

05388

13 W Injection nozzle assembly 19

[Disassembly]

CAUTION&-------------• Do not touch the sliding parts A of the needle valve 19. • Do not change the needle valve 19 and nozzle 18 combination on each cylinder.

06932

[Cleaning] Wash the needle valve 19 and nozzle 18 in gas oil, then use the �a Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 19 using the Cleaning Bar of the [t]a Cleaning Tool Set.

CAUTION&-------------Do not use a wire brush or any hard metallic object for cleaning.

018921

• Remove carbon from the injection orifice of the nozzle 18 using the Needle Cleaner of the �]a Cleaning Too! Set. Insert the needle cleaner and rotate it to dislodge the carbon. Cleaning needle diameter: 0.31 mm or smaller.

01893

• Clean the seat of the nozzle 18 using the Cleaning Scraper of the �a Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

�]a

01894

[Inspection] • Wash the needle valve 19 and nozzle 18 in gas oil, then fit them togeth er. • Pull up the needle valve 19 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 19 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 18 as a set.

·19

01911

13A-55

INJECTI N NO

LE <2-spring

· BOSCH AU

MOTIVE SYSTEMS>

NOTE

After replacing any nozzle 18, be sure to readjust the prelift and ensure that the valve opening pressure is up to specification.

[Adjustment] During reassembly, make adjustments in the sequence shown below.

CAUTION_&-------------

• Before making adjustments, wash all parts in gas oil and ensure that they are free of dirt and other foreign material. • Do not touch the sliding surfaces of the needle valve 19.

I•

Select prelift adjustment shim

I• I•

Install prelift shim Check prelift

Inspection * Carry out if necessary.

JJA-56

13 • Adjusting nozzle opening pressure (1st valve opening pressure) • Fit the nozzle 18 and needle valve 19 into the nozzle holder using the [,gb Retaining Nut for Adjustment and [,&Jc Gasket.

NOTE

• Before tightening the [,gb Retaining Nut for Adjustment, check that the pin 20 is fully seated in the nozzle 18. Tighten the retaining nut to finger tightness, then tighten it to the specified torque us ing a torque wrench. Specified torque: 59 to 79 N · m {6 to 8 kgf · m}

• Remove the bolt from the end of the [gb retaining nut

20 18

182401

• Insert the 1st push rod 16, 1st spring 15, valve opening pressure ad justment shim 4, and spacer 13 into the nozzle holder. (For the time be ing, use a shim of approximately 1 mm in thickness.) Then, tighten the set screw 10 to the specified torque.

18241

13A-57

INJEC ON NO

LE <2-spring

: BOSCH AU

MOTIVE SYSTE S>

• Fit the nozzle holder 21 onto the nozzle tester A and measure the 1st valve opening pressure. • If the measurement is out of the specification, adjust by shim 1 4. Shims are available in the following thicknesses: 0.50, 0.52, 0.54, 0.56, 0.58, 0.60, 0.70, 0.80, 0.90, 1.00, 0.10, 0.20, 0.30, and 0.40 mm.

NOTE

18242

• Before using any shim, check its thickness using a micrometer. • These shims are also used for prelift adjustment. • A 0.02 mm change in shim thickness corresponds to a 24 kPa {2.4 kgf/cm2} change in valve opening pressure. • Leave the bolt off the end of the Retaining [.gb Nut. • Selecting prelift adjustment shim • Fit the [.ge Dial Gauge onto the [.gd Adjusting Device. Then, fit the 2nd push rod 11 into the �f Base and mount the assembly in a vise. Next, set the [.gg Pin and Adjusting Device as shown in the illustration, and zero the Dial Gauge. • Fit the 2nd push rod 11 into the nozzle holder.

NOTE

Do not install the 2nd spring 11 and prelift adjustment shim 12.

11 [.gf

18243

• Using the intermediate screw A of the [.gd Adjusting Device, mount the Adjusting Device on the set screw 10. Then, hold the holder B of the [.ge Dial Gauge and move it up and down to check that the gauge oper ates smoothly. Still holding the holder of the dial gauge, push down the gauge and read its lift measurement h.

NOTE

Read to a precision of 1/100 mm.

A 10

• Select the prelift adjustment shim 12 as follows: t = t' + h t: Shim thickness (as measured) where t': Prelift (nominal value) h : Dimension measured in previous step of procedure T: t ± 0.015 mm T t ± 0.015 mm where T: Thickness of shim to be used • Remove the [.gd Adjusting Device from the nozzle holder 21.

13A-58

13 • Adjusting 2nd spring setting pressure (open pressure)

a--®

• Fit the 2nd spring 9 and adjusting screw 7 into the nozzle holder 21 . • Tighten the lock nut 8 to the specified torque.

7--1 9

NOTE

Do not install the prelift adjustment shim.

21 18245

• Measure the 2nd spring setting pressure (open pressure) using the nozzle tester A.

NOTE

Leave the bolt off the end of the lgb Retaining Nut.

• If the measurement is out of the specification, adjust by the adjusting screw 7. Nominal value: 24.7 to 25.3 MPa {252 to 258 kgf/cm2} �182421

.. ..tt.fter adjustment, tighten the lock ni_it R tn thA �rAr.ifiArl torque. • Adjusting needle valve full lift • Fit the special tools shown in the illustration, then zero the lge Dial Gauge. lgh Connector tightening torque: 39 to 49 N · m {4 to 5 kgf · m}

A: Bolt • Fit the nozzle 5 onto the nozzle tester, then operate the nozzle tester lever to bleed all air out of the lgb Retaining Nut (for adjustment). Also, check for fuel leaks. • Using the nozzle tester lever, increase the pressure to 34.3 to 44.1 MPa {350 to 450 kgf/cm2} such that the nozzle's needle valve 19 lifts fully. Read the lift dimension shown by the Dial Gauge. • Remove the �e Dial Gauge, �h Connector, and �j Pin.

18246

13A-59

INJECTION N

LE <2-spring

: BOSCH AUTOMOTIVE SYSTE S>

• Installing prelift adjustment shim

• Remove the set screw 1 0, lock nut 8, and adjusting screw 7 from the nozzle holder 21 as an assembly.

...IU "

CAUTiON

Do not loosen the lock nut 8. Loosening the lock nut would alter the 2nd spring setting pressure.

18247

• Fit the prelift adjustment shim 12 between the spacer 13 and push rod 11. Use the shim selected previously in accordance with the "Selecting Prelift Adjustment Shim" procedure. • Install the 2nd push rod 11 and 2nd spring 9. • Fit the set screw 10, lock nut 8, and adjusting screw 7 as an assembly, and tighten the set screw to the specified torque. • Measure the needle valve lift in accordance with the previously described procedure. The lift measured this time should be the value of "(full lift) (prelift)".

• Checking prelift • Check the pre lift based on the previously mP.a!=:mP.rl "f1 ,11 lift" B.nd "!!ft'' dimensions. L S=l0.e where e 0.02 � � e � e + 0.02 � e: Prelift (as measured) e: Prelift (nominal value) L: Needle valve full lift dimension (as measured) S: Needle valve lift dimension (as measured) with prelift subtracted If� e is out of the specified range (f ± 0.02 mm), replace the prelift ad justment shim 12 in accordance with the previously described proce dure, then repeat the last two procedures such that the� e dimension falls within e ± 0.02 mm. Select the thickness of the replacement shim (t') as follows: t'=t+(f �€) T = t' ± 0.015 mm t: Thickness of shim installed t': Shim thickness T: Thickness of shim to be used e: Prelift (nominal value)

13A-60

• Checking 2nd spring setting pressure {cover pressure) • Check the prelift in accordance with the previously described proce dure. Then, use the nozzle tester to increase the pressure again to 34.3 to 44.1 MPa {350 to 450 kgf/cm 2 } such that the needle va!ve 19 lifts ful ly.

NOTE

The �b Retaining Nut {for adjustment) must have its end bolt fitted.

• With the needle valve 19 fully lifted, stop operating the lever of the nozzle tester A. The pressure will start to decrease, and the needle valve will drop. • At the moment when the nozzle lift decreases to 0.05 mm, read the pressure gauge indication. Nominal value: 23.1 to 23.6 MPa {235 to 240 kgf/cm2 } • If the measured value is out of specification, adjust it. UJ P.13A-59 • Remove the special tools.

• Inspection • Fit the injection nozzle assembly 5 onto the nozzle tester A, then check the 1st valve opening pressure, the spray condition, and the airtight ness of the seat. Check also for fuel leaks.

NOTE

If the 1st valve opening pressure is out of specification, make ad justments again starting with the preliminary procedures.

01910

13A-61

INJE

ZZLE <2-spring

pe: DENS > • Pre-disassembly inspection l J ! P.13A-63 • Disassembly sequence

1 Eyebolt 2 Fuel leak-off pipe 3 Injection pipe

4 Bolt 5 Injection nozzle assembly 6 Cap nut 7 Lock nut 8 Screw plug 9 Shim (for adjusting valve opening pressure) 10 2nd spring 11 2nd push rod 12 Shim (for adjusting prelift) 13 Capsule screw 14 1st spring i5 1st push rod 16 Retaining nut i7 Nozzle 18 Needle valve 19 Pin 20 Nozzle holder 21 Nozzle holder joint 22 Dust seal 23 Gasket

06�

01-i

oa--w 9-----®

10-�

20-

11-{

18249

0: Non-reusable part • Assembly sequence Reverse the order of removal.

WARNING_& ------------------------ To minimize the risk of fire, wipe up any spilled fuel.

NOTE

Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly.

CAUTION_&--------------------------

Under no circumstances change the needle valve 18 and nozzle 17 combination used in each injection nozzle assembly 5.

NOTE

When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

JJA-62

13 Service standards

Unit: mm Maintenance item

Location 5

Injection pressure Prelift

1st valve opening pressure

'-·---

2nd valve opening pressure (cover pressure)

16.67

+g.

Standard value 9a

MPa {17o

6o 6

0.08 ± 0.02

[

Parts to be tightened

Tightening torque

Eyebolt (fuel leak-off pipe mounting)

Injection pipe union nut

Bolt (injection nozzle mounting)

Cap nut

39.2 to 49 {4 to 5}

7 8

Lock nut

58.8 to 68.6 {6 to 7}

Screw plug

29.4 to 39.2 {3 to 4}

Retaining nut

58.8 to 78.5 {6 to 8}

Adjust

Unit: N · m {kgf · m}

Adjust

21.57 +g. 9a MPa {220 + ° kgf/cm2 }

0 Tightening torques Location

Remedy

Limit -

kgf/cm 2 }

Remarks

15 to 20 {"1 .5 to 2.0} 25 {2.5}

12 to 14 {1.2 to 1 .4}

I Nozzle holder joint

58.8 to 68.6 {6 to 7}

� Special tools Location

Tool name and shape

Part No.

Nozzle Cleaning Tool 2-Spring Nozzle Adjustment Tool

Holder

Probe

[£la *105789-0010 [£lb [gc

*95091-10770

Application Cleaning nozzles Measuring prelift

* DENSO product number * BOSCH AUTOMOTIVE SYSTEMS product number

♦ Service procedure • Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for in spection.

NOTE

Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement.

(1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the shims 9, 12. • If the measurement is still out of specification after adjustment, re place the injection nozzle assembly 5. 01910

WARNING&------------Do not touch the spray that comes out of the nozzle.

JJA-63

ZZLE <2-spring

INJECTI �

(2) Inspecting spray condition

Bad

Good

1 A

lI l t

111

}

pe: DENS >

06931

• Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke and maintain a continuous spray. B: Even spray from aii five injection orifices (Good) C: Even and symmetrical spray (Good) D: Asymmetrical spray (Bad) E : Branched spray (Bad) F: T hin spray (Bad) G: Irregular spray (Bad)

WARNING

Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks

• Slowly increase the nozzle pressure to 1.96 MPa {20 kgf/cm2 } below the specified 1st valve opening pressure. Maintain this pressure tor 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly still appears defective, it must be replaced. Bad

Good

05388

[]] Injection nozzle assembly 18

[Disassembly]

CAUTION&_--------------

• Do not touch the sliding parts A of the needle valve 18. • Do not change the needle valve 18 and nozzle 17 combination on each cylinder.

06932

�a

[Cleaning] Wash the needle valve 18 and nozzle 17 in gas oil, then use the (&]a Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 18 using the cleaning bar of the �a Cleaning Tool Set.

CAUTION

Do not use a wire brush or any hard metallic object for cleaning.

01892

13A-64

13 • Remove carbon from the injection orifice of the nozzle 17 using the needle cleaner of the �a Cleaning Tool Set. Insert the needle cleaner and rotate it to dislodge the carbon. Cleaning needle diameter: 0.315 mm or smaller.

01893

• Clean the seat of the nozzle 17 using the cleaning scraper of the (ga Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

018941

01911

[Inspection] • Wash the needle valve 18 and nozzle 17 in gas oil, then fit them togeth er. • Pull up the needle valve 18 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 18 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 17 as a set. [Adjustment] During reassembly, make adjustments in the sequence shown below.

CAUTION&--------------

• Before making adjustments, wash all parts in gas oil and ensure that they are free of dirt and other foreign material. • Do not touch the sliding surfaces of the needle valve 18.

I•

Adjust 1st valve opening pressure

•

I• I•

pressure Adjust prelift Check 1st valve opening pressure

13A-65

INJECTI

ZZLE <2-spring

pe: DENS

• Adjusting 1st valve opening pressure (injection pressure) • Assemble the parts as shown in the illustration.

NOTE

Check that the pin i 9 is fully seated in the nozzle 17 before tight ening the retaining nut 16 to the specified torque.

• Fit the injection nozzle assembly onto the nozzle tester, then adjust the valve opening pressure of the 1st spring by loosening the capsule screw 13. • Lock the capsule screw 13 in position and tighten the lock nut 7 to the specified torque.

• Adjusting 2nd valve opening pressure

1�--

• Fit the 2nd push rod 11, 2nd spring 10, valve opening pressure adjust ment shim 9, and screw plug 8. If the thickness of the valve opening pressure adjustment shim is not known, a 1.9 mm shim should be used as a guide.

®-----9 10

NOTE

Do not install the prelift adjustment shim 12.

• Fit the assembled arrangement onto the nozzle tester, then adjust the shim 9 thickness to achieve the specified nominal injection pressure. Shims are available in thicknesses from 0.50 to 2.50 mm.

NOTE

• A 0.02 mm change in shim thickness corresponds to a 22 kPa {2.2 kgf/cm2} change in valve opening pressure. • These shims 12 are also used for prelift adjustment.

01914

• Adjusting prelift • Remove the screw plug 8, valve opening pressure adjustment shim 9, and 2nd spring 10. Then, assemble the dial gauge A, lgb Holder, and lgc Probe as shown in the illustration. • Zero the dial gauge A.

20 01915

JJA-66

• Remove the 2nd push rod 11 and fit the prelift adjustment shim 12. Then, refit the dial gauge as described above and note the needle deflection. If the prelift measurement is out of specification, adjust it by changing the shim.

019161

• Checking 1st valve opening pressure

;=:

• Assemble the parts shown in the illustration.

NOTE

Be sure to use the shims 12 selected in accordance with the pro� cedures described earlier. Take care not to confuse the valve opening pressure shim 9 with the prelift shim 12.

@'------9

�,------10

• Fit the injector nozzle assembly onto the nozzle tester and check the 1st valve opening pressure.

�11

NOTE

If the1st valve opening pressure is out of specification, carry out the entire adjustment procedure again.

@--- 12

01917

13A-67

SPECIFICATIONS ........................................

14-2

STRUC TURE AND OPERATION 1. Cooling System (Water Flow).................................... 2. Water Pump.................................................... 3. Thermostat ..... . ............................. . ....... . ........

TROUBLESHOOTING .....................................

14-2 14-3 14-3

14-4

t"'UJ.\/l=Ml�I I= IN�Pl=�TlnN ANn An.11 l�TM!=NT

1. Replacing Coolant and Cleaning Coolant System ................. 2. Air Bleeding of Cooling System ................................ . 3. Gas Leak Testing ...............................................

14-6 14-8 14-8

RADIATOR ..............................................

14-9

COOLING FAN AND V-BELT ...............................

14-10

WATER PUMP

14-14

T HERMOSTAT

14-18

14-1

NS/ STRUCTURE AND

SPE

SPECIFICATIONS Specifications

Item

Forced water circulation type

Cooling system Water pump type

Belt-driven involute type

Thermostat type

Wax pellet, bottom bypass type (with jiggle valve) Constant control type

Automatic cooling fan coupling type

Tube and corrugated fin type

Radiator type

13 {13}

Coolant capacity dm 3 {L} (engine main body only)

STRUCTURE AND OPERATION 1. Cooling System (Water Flow) 1 ReseNoir tank Thermostat

2 3 4 5 6 7 8 9

9 a--5

7 16951

14-2

Cylinder head Drain plug Oil cooler Water pump Drain cock

Radiator Bypass hose

14 2. Water Pump <With cover>

---

_______ 1

/7 _,-/�

2 �

2�

-�

16934

16935

8 Washer 9 Impeller

1 Water pump shaft

Flange Snap ring Bearing Spacer Bearing 7 Water pump case 2 3 4 5 6

10 Cover 11 Unit seal

A: Drain hole

3. Thermostat 1 Thermostat cover 2 Thermostat 3 Thermostat case

A-

A: To radiator B: With low coolant temperature C: With high coolant temperature D: From cylinder head E: To water pump

E 06361

Thermostat 2 is a bottom bypass type that uses wax-charged pellets as its regulating element. As the wax changes from solid to liquid in line with temperature increases, the total wax volume changes. As a result, the position of the valve, changed by the coolant temperature, regulates the flow of coolant to the radiator and water pump (bypass side) and controls the coolant temper ature.

14-3

UBLESH Symptoms

·u 0)

(/J (/J

:E ::J

(/J

20)

-� 0)

> 0

Possible causes V-belt

Loose or damaged

ci>

> 0

Water pump

Unit seal defective Loose fit between shaft and flange and/or shaft and impeller

Case fitted poorly Gasket defective

0 0

Valve opening temperature too high; valve remains closed

Water pump fitted poorly Gasket defective Bearing defective Impeller defective

Thermostat

0 0 0 0 0 0 0

Gasket defective

()

Cooling fan

Fan shroud fitted poorly

Automatic cooling fan coupling

Bearing defective Bimetal damaged Bimetal contaminated with foreign particles Silicon oil leaking Oil cooler fitted poorly Gasket defective

Coolant quantity insufficient and/or coolant dirty

()

Coolant passages dirty and/or clogged

()

Hoses fitted poorly

Ambient temperature extremely low

14-4

<t:

(l)

·w>

Cylinder head fitted poorly

Space between core and fins clogged Pressure cap not sufficiently airtight

Cylinder head

C ..0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 () 0 0 ()

Core cracked and/or separation of soldered joints

Oil cooler

ct!

Valve opening temperature too low; valve remains open Water leaking from water temperature sensor Radiator

al E

0 0

0 0 0 0 0 0 0

·aC

(/)

Excessive tension Oil on belt

Remarks

()

0 ()

Gr 12 Gr 11

14-5

N-VEHICLE INSPECTI

ADJUST ENT

1. Replacing Coolant and Cleaning Coolant System 1 Pressure cap 2 Crankcase drain plug 3 Radiator drain cock

16941

Unit: N · m {kgf · m}

Using the radiator for extended periods without cleaning the cooling system will cause overheating since rust and scale de posits will accumulate. T he cooling system must be cleaned periodically. • Draining coolant Before draining the coolant, loosen pressure cap 1 to reduce the pressure in the cooling system.

WARNING&-------------------------

• To avoid being scalded, ensure that the coolant has cooled sufficiently before draining it out. • Unless care is exercised, opening pressure cap 1 when the coolant is hot can cause the coolant to spray out. Cover the pressure cap with a cloth, and loosen the cap slowly to bleed off the pressure before opening it fully. • Cleaning procedure • Run the engine and keep the coolant at a temperature of approximately 90 ° C so that the thermostat valve remains open and the coolant continues to circulate in the radiator. • To increase the coolant temperature quickly, cover the front of the radiator with cardboard or a similar material. • If cleaning is carried out after a large amount of rust has accumulated, the radiator may start to leak. Carefully examine the radiator for leaks after cleaning the cooling system. • Soft water to be used should have the following properties.

CAUTION&------------------------Do not use hard water as it causes scale and rust.

Required propertiies of soft water

14-6

14 Method of cleaning the cooling system depends on its condition. • Clogged radiator

• Extremely dirty coolant

• Ordinary condition

Cleaning method by water

Cleaning method using cleaning solution (FUSO Radiator cleaner Radipet 7) I Drain the coolant.

(Work procedure)

;

Make a solution of FUSO Radiator Cleaner (Radipet 7) at a rate of 5 to 10% to the total volume of coolant. I Fill the radiator with the solution. Keep the solution temperature at 90 ° C and let the engine idle for 30 minutes.

CAUTION&--------Be sure to allow the engine to idle for 30 min utes only. Circulating the solution in the sys tem for more than an hour might cause the system to breakdown.

Fill with soft water (boiled preferably). Keep the water temperature at 90 ° C and let engine idle for 10 minutes. Drain the water. If the drained water is clear, cleaning has been successful. If it is still muddy, repeat the procedure.

DANGER&_------------------------

lf you accidentally splash FUSO Diesel Long Life Coolant, Fuso Antifreeze, or Radiator Antirust (Radipet 9) in your eyes, wash it out immediately with water and seek medical attention.

WARNING

FUSO Diesel Long Life Coolant is flammable. Keep them away from heat and flames.

NOTE

• After cleaning the cooling system with cleaning fluid, fill it with coolant as son as possible. • To prevent freezing of the coolant and corrosion of the cooling system, add to the coolant the specified proportion of FUSO Diesel Long Life Coolant. (See the Maintenance Manual for instructions on the use of these products).

14-7

N-VEHICLE INSPE

NAND

ENT

2. Air Bleeding of Cooling System • Remove the pressure cap. Keeping the coolant temperature at 90 ° C, let the engine idle until the cooling system is com pletely bled of air. While the engine is idling, keep the heater controller's adjustment lever at its maximum-temperature position so that coolant flows freely in the heater piping. • After bleeding the cooling system of air, add coolant to the radiator and reservoir tank as required.

3. Gas Leak Testing The presence of air or exhaust gas in the coolant increases corrosion and rust in the cooling system. Check for air or exhaust gas in the coolant using the following procedure: • Remove pressure cap 1.

WARNING&_-------------

Make sure the coolant is sufficiently cool before loosening the pressure cap. If the coolant is hot, it will spray out

• Run the engine until the coolant temperature reaches approximately 90 ° C. • if bubbles A appear continuously, there is air or exhaust gas in the cool ant. • If the coolant contains air, the cylinder head bolts, water pump mount ing bolts, or hose connections may be loose. Alternatively, the hoses may be damaged. • If the coolant contains exhaust gas, it is possible that the cylinder head gasket is damaged or that the cylinder head is cracked.

14-8

• Disassembly sequence

1 Wire net 2 Shroud

�

3 Frame 4 Drain cock 5 Drain hose 6 Pressure cap 7 Radiator • Assembly sequence Reverse the order of disassembly.

16943

Service standards Location

Maintenance item

Standard value 69 ± 15 kPa {0.7 ± 0.15 kg/cm 2 }

Pressure valve opening pressure

Radiator air leakage (with air pressure of 150 kPa {1.5 kgf/cm 2 })

0 cc

Limit -

Remedy

Correct or replace

Replace

♦ Service procedure

W Pressure cap inspection Measure the pressure valve's opening pressure. If the measurement does not conform with the standard value, replace pressure cap 6.

6 00194

[I] Radiator inspection • Fit hose A and radiator cap tester B to the radiator upper tank. • Fit plug C to the lower tank, then immerse the radiator in a tank of water. • Using radiator cap tester B, apply the specified air pressure of 150 kPa {1.5 kgf/cm2 }, and check for air leakage. • If air leakage is apparent, correct or replace radiator 7.

1----

07386

14-9

• Disassembly sequence 1 V-belt 2 Automatic cooling fan coupling 3 Cooling fan 4 Spacer 5 Water pump pulley *: Water pump assembly P.14-14 • Assembly sequence Reverse the order of disassembly.

CAUTION&_-------

16946

• Automatic cooling fan coupling 2 is an integrated unit and cannot be disas sembled. If any fault is apparent, replace the whole assembly. • When replacing V-belts 1, be sure to re place them as a set to maintain even ten sion between them.

16947

Service standards

Unit: mm

� Special tools Location

Tool name and shape

Part No.

Application

Q � >=

Belt tension gauge

MH062345

� j

14-10

03612

V-belt tension measurement

14 ♦ Service procedure

IT] V-belt

[Inspection] Apply force of approximately 98 N {10 kgf} to the center of the V-belt 1 and measure the extent of V-belt deflection A. B: Alternator pulley C: Water pump pulley D: Crankshaft pulley

16948

• Set upper O-ring E of� belt tension gauge to 8 N {10 kgf} (push load) on scale F. • Set lower O-ring G of[&] belt tension gauge to the V-belt's correct maxi mum deflection value on scale H.

03613

• Apply the �J belt tension gauge to the center of V-belt 1 and push until O-ring E reaches the flange K.

03614

• Measure the extent of V-belt 1 deflection A. If the measurement does not conform with the standard value, adjust the V-belt as shown below.

03615

14-11

[Adjustment]

CAUTION&--------------

00203

• Excessive tension in V-belt 1 may damage the belt and related bearings. • Be sure to replace the V-belts 1 as a set to maintain even tension between them. • Keep V-belt 1 free of oil. If the belt becomes oily, it will slip, result ing in overheating of the engine and insufficient charging of the battery. <Type A> • Loosen alternator mounting bolts L (2 places) and adjust the V-belt tension by moving alternator M to the left or right. • When the adjustment is complete, tighten the bolts and nuts securely. <Type B> • Loosen alternator retaining bolts L (2 places) and adjust the tension of V-belt 1 using adjuster bolt N. • After the belt tension is adjusted, tighten the bolts and nut firmly.

®47060

[1] Automatic cooling fan coupling

16949

[Inspection] Inspect automatic cooling fan coupling 2 in accordance with the following procedure. If any defect is evident, replace the unit. • Check for leakage of oil from the coupling body. • Rotate automatic cooling fan coupling 2 by hand and check for irregular movement or abnormal noise caused by a defect in the bearing. • Check for excessive axial play in automatic cooling fan coupling 2 when the engine is cool. [Cleaning] If any foreign particles have adhered to bimetal A, brush them off gently.

16950

14-12

14-13

ER PU P

• Disassembly sequence 1 Bolt 2 Water pump assembly

10 Water pump shaft 11 Unit seal 12 Grease nipple 13 Water pump case 14 Gasket (pump with cover) 15 Cover (pump with cover) 16 Gasket

3 Impeller 4 Flange

5 Snap ring 6 Bearing 7 Spacer 8 Bearing 9 Washer

0: Non-reusable part

• Assembly sequence 16-15----+14-2-1 2 :

113 - 12 ------- ) 5 10 � 9 � 8 -• 7 � 6

• Inspection after assembly P.14-16

14-14

➔

. 3 . 411 -

14 Service standards

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Location

Limit

3, 10

Impeller-to-water pump shaft interference

[13) 0.03 to 0.06

4,10

Flange-to-water pump shaft interference

[26] 0.05 to 0.08

0 Tightening torque

Remedy Reassembly allowed only twice Reassembly allowed only twice

Unit: N · m {kgf · m} Remarks

Location

� Lubricant and/or sealant Specified lubricant and/or sealant

Points of application

Location

Quantity

Bearings

Wheel bearing grease fNLGI No. 2(Li soap)]

As required

Unit seal outer periphery

THREEBOND i102

As required

Grease nipple

vVheei bearing grease [NLGI No. 2 (Li soap))

6,8

60g

l&] Special tools Location

Unit: mm Tool name and shape

Part No.

Impeller Puller

MH06i417

Application

Removing impeller

16927

14-15

ER PU P ♦ Service procedure • Inspection after assembly • After assembly, rotate flange 4 by hand and check that it turns smoothly without hindrance. • If the flange does not turn smoothly, disassemble and inspect the water pump again.

16928

� 3

W Impeller [Removal] �: Impeller Puller

16929

[Installation]

CAUTION&--------------

®46285

• Before refitting impeller 3, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the impeller can be refitted. Ensure to punch a mark in location A for future reference before refitting the impeller. • The punch mark is used to show how many times in the past impeller 3 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the impeller again. Replace it with a new impeller. Press-fit impeller 3 until its end face B is in line with end face A of water pump shaft 10. C: Press

NOTE

Press-fit the impeller such that flange side D of water pump shaft 1 O is the load receiving surface.

16930

14-16

14 @] [iQ] Impeller-to-water pump shaft interference

If the measurement does not conform with the standard value, replace the defective part( s).

CAUTION.LG.--------------

Even if the standard value is satisfied, reassembly must not be carried out more than twice.

[!] Flange [Removal] A: Gear puller

16932

®46284

J---

CAUTION/!\·-·=--�---------------

• Before refitting flange 4, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the flange can be refitted. Ensure to punch a mark in location A for future reference before refitting the flange. • The punch mark is used to show how many times in the past flange 4 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the flange again. Replace it with a new flange. [Press-fitting] With a load of 9,810 N {4,000 kgf}, press-fit flange 4 until it touches bearing 6.

,f B

��---'-s,

[Installation]

'----'

B: Press C : Cylindrical jig

6 20 mm or mor�

16933

[!] [!QJ Flange-to-water pump shaft interference If the measurement does not conform with the standard value, replace the defective part( s).

CAUTION.LG.--------------

Even if the standard value is satisfied, reassembly must not be carried out more than twice.

14-17

THER

16945

16944

• Disassembly sequence 1 Water temperature sensor

8 9 10 11

2 Thermostat cover 3 Gasket 4 Thermostat 5 Bolt 6 Thermostat case 7 Gasket

Front hanger Bypass hose O-ring Joint

0: Non-reusable part

NOTE

Do not remove thermostat case 6 and front hanger 8 unless they are leaking water or otherwise defective.

• Assembly sequence Reverse the order of disassembly.

Service standards Maintenance item

Location

Water temperature sensor resistance (Between terminal n ; and body)

so c

Thermostat

Valve opening temperature

ao c 100°c

Valve lifVtemperature

14-18

Standard value

Limit

76.s ± 2° c

10 mm or more at 90 ° C

(136 .Q) 48 ± 5 .Q 27.2 ± 2 .Q

Remedy Replace

Replace

14 0 Tightening torque

Unit: N · m {kgf · m}

� Lubricant and/or sealant

♦ Service procedure [}] Water temperature sensor inspection • Place water temperature sensor 1 in a container of engine oiL • Heat the oil until it reaches the specified temperatures. Stir the oil to ensure that it heats up evenly. • Measure the resistance between terminal and body (2 of the water 1

tvl I lj.Jvl atLII v ;:,c;11;:)VI,

• If the measurements do not conform with the specified values, replace the water temperature sensor 1.

[!] Thermostat inspection -- C

Place the thermostat in a container of water. While stirring the water with a rod A to ensure that it is heated evenly, carry out the following inspection procedure. If the measurements do not conform with the standard values, replace the thermostat 4. (1) Valve opening temperature

00218

• Support thermostat 4 with wire E to keep it away from heat source D. • Gradually heat the water until it reaches the valve opening tempera ture. • Maintain this temperature for 5 minutes and check that valve B is open. • When the water temperature drops below 65 ° C, check that valve B is completely closed. C: Thermometer (2) Valve lift Heat the water to slightly higher than the valve opening temperature. With valve B fully open, maintain this water temperature for 5 minutes. Measure the extent of valve lift F.

14-19

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-2

STRUCTURE AND OPERATION 1. Air Cleaner ..................................................... 2. Cartridge Type Air Cleaner ...................................... 3. Pre-Cleaner .................................................... 4. Dust Indicator .................................................. 5. Turbo Charger ................................................. -rnn; 1r,1 C�Ul"\l"\TIM� 1

nvua;;,1..�v• •'-''-' 1 11-.""'

15-3 15-4 15-4 15-5 15-6

15-9

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

ON-VEHiCLE iNSPECTiON AND ADjUSiiviENT 1. Inspection of Dust Indicator

15-10

AIR CLEANER

<FHG, FWG> .•••••••••••.••..••••••••••••••••••••••••••••• <FTG> ••.••••••.••••••.•••••..••••.••••••.•••••••.•

15-12 15-16

<Cartridge> ••••••••••••••.•.•••••••••••••••••••••••••••••

15-19

•

TURBOCHARGER

<T048, T04E (6016-PT)> <T04E (6016-TL), TBP4> <TF07> •••••••••••••••••••••••••••••••••• Ill

•

■

15-20

•

INTERCOO LER

<6016-TL, 16-TLE> •••••••..•• . ••••••••••••.••••••••••••••.•

INTAKE MANIFOLD

15-30 15-42

15-52

<6014, 16, 16-E> •.•••.••••.••..•••••••.. . .•••••• • ••.••••••• <6014-T, 15-T, 16-T, 16-PT> ••••.• • ••••••.••••••.••.•••••••••••

15-54 15-56

<6016-TL> ••• • ••••••••••••••••••••••••.••••••••••••••.••• <6016-TLE> •••••.••••.•.•••..• • .••••.••..•••.•.••.•••••••

15-58 15-60

EXHAUST MANIFOLD

<6014, 16, 16-E> •••••• • •.•..••. • • ••.• . ••••.• • ••••• . •• . ••..•

15-62

<6014-T, 16-T, 16-PT, 16-TL, 16-TLE> ••••.••• . • •••••.•••••••••••

15-63 15-64

<6014-T, 15-T, 16-T, 16-PT, 16-TL, 16-TLE> •••• • •.••• • •••••••••••

15-1

SPECIFI

Air cleaner element

Dust indicator

Turbocharger T048

T04E

TF07 Mitsubishi

lntercooler

15-2

STRU TURE AND

1. Air Cleaner Cyclone type air cleaner <FHG, FWG> 1 Element 2 Vane <Single element type>

18251

A: Outside air B:To engine

18252

1 Element 2 Guide vane 3 Vacuator valve

A: Outside air B: To engine

2 18253

18254

The element 1, which comes in two types; the single and double element types, is the filter paper type. Coated with plastics and given heat treatment, the element offers outstanding resistance to water and oils. The air that has been drawn in is made to rotate by the guide vane 2, and large particles of dust are centrifugally separated. Furthermore, small particles of dust are filtered out by the filÂ ter paper element, and the air thus made clean is drawn into the engine. The vacuator valve 3 automatically discharges the separated dust and dirt. When the engine speed lowers to a certain speed, the elasticity of the rubber valve overcomes the negative pressure in the air cleaner, thus opens and disÂ charges the dust and dirt C.

18268

15-3

STRU TURE 2. Cartridge Type Air Cleaner

1 Element 2 Inlet slot A: Outside air B: Into engine The element 1 is the filter paper type. The outside air is directly drawn in from the inlet slot 2 of the air cleaner proper.

18266

3. Pre-Cleaner 1 Pre-cleaner body 2 Guide vane A: Outside air B: To air cleaner 1

The pre-cleaner removes relatively large particles of dust conÂ tained in the air that has been drawn in. The air that has been drawn in is made to rotate by the guide vane 2 in the pre-cleaner, and the centrifugally separated parÂ ticles of dust are accumulated in the pre-cleaner body 1.

B 18267

15-4

15 4. Dust Indicator <Mechanical type> 1 Dust indicator 2 Signal .3 Spring 4 Transparent portion 5 Reset button

5 1

A: Negative pressure

18269

The mechanical type dust indicator 1 is located near the intake air outlet of the air cleaner. Operated by the negative pressure which is produced when the air is drawn into the engine, the dust indicator indicates that it is high time to clean or replace the element. In other words, when the element is clogged with dust, the sucÂ tion resistance increases. When the negative pressure A reachÂ es 6.23 kPa {635 mmH2O}, the signal 2 (red) is pulled down against the spring pressure of the spring 3. So the signal (red) appears in ihe irc111SJJdlent poition 4 of the body to indicate that it is high time to clean or replace the element. After cleaning or repiacing the element, press the reset button 5, and the signal will return to its original position.

<Electric type> 2

1 Dust indicator 2 Warning lamp 3 Starter switch 4 Battery 5 Air cleaner

A: Negative pressure

When the negative pressure A reaches 6.23 kPa {635 mmH20}, the electric type dust indicator closes its contact to light the warning lamp 2 and alert the driver that it is high time to clean or replace the element. 18270

15-5

STRUCTURE

5. Turbo Charger <T04B, T04E (6D16-PT)> 4

1 2 3 4 5

6 7 8 9

10 11 12 13 14

Compressor housing Piston ring Thrust collar Thrust bearing Center housing Wheel shroud Turbine housing Turbine wheel Piston ring Retaining ring Bearing Seal ring Back plate Compressor wheel

18271

<TF07>

1 Compressor cover 2 Piston ring

3 Snap ring

4 Insert

5 Thrust bearing 6 Bearing housing

7 Turbine back plate 8 Turbine housing 9 Shaft & turbine wheel assembly 10 Piston ring 11 Bearing 12 Oil deflector 13 Thrust ring 14 Snap ring 15 Thrust sleeve 16 Compressor wheel

15-6

13 12

18272

15 <T04E (6D16-TL), TBP4>

1 2 3 4 5 6 7 8 9 1O

12 13

Compressor housing Piston ring Thrust collar Thrust bearing Center housing Wheel shroud Exhaust coupler Actuator assembly Turbine housing Turbine wheel Piston ring Retaining ring Bearing Seal ring Back plate Compressor wheel

11 18273

15-7

STRU TURE

• Waste gate mechanism <T04E (6O16-TL), TBP4> • The waste gate mechanism has the actuator assembly 8 to let extra exhaust gas escape. By so doing, the boost pressure is properly con trolled to prevent the turbine wheel from overrunning and prevent an excessive pressure produced in the intake manifold. • The boost pressure is led from the compressor housing 1 through a rubber hose to the chamber A of the actuator assembly 8. When the boost pressure that acts on the chamber A is below the setting, the ac tuator assembly does not operate, and the waste gate valve remains closed, and the exhaust gas Dis blown against the turbine wheel 10. B 8 A

01510

• When the boost pressure that acts on the chamber A exceeds the set ting, the waste gate valve is opened. As a result, the amount of exhaust gas blown against the turbine wheel 10 decreases, and the rotating speed of the compressor wheei 16 aisu decreases, and the boost pres sure falls.

01511

• Operation of overboost valve • The overboost valve E operates when the boost pressure becomes ab normally high due to the failure of the waste gate mechanism.

01512

• When the boost pressure F of the overboost valve E exceeds the set ting, the valve releases the boost pressure into the atmosphere to make sure that a boost pressure more than necessary is not applied to the engine. The valve whistles when it is in operation.

01513

15-8

TR UBLESH Symptoms

co Q)

"�

:5 co

(/)

�

..c

C "6) C

(/)

O> ::I

co ><

..::.c:

(.)

O> ::I

co ><

C "6) C

"[5

2 �::I

� ,_

(/)

·:::;:

(.)

·5 >

·u5 (/)

(I)

(.)

-0 C

Q) +-::::i (/) 0 >, (/)

O> U) C :,

co co ,_ .c ><

+J (j)

Turbine wheel interfering with wheel shroud and

Turbine wheel interfering with turbine housing Damaged turbine wheel

0 0 0

Compressor wheel interfering with compressor housing

Thrust sleeve, thrust collar and thrust bearing seizure

Damaged compressor wheel

Turbocharger

Defective bearing Carbon deposited on turbine wheel

"· .......... :

__ _,,.,, ..

...... ,...,, lUI UII IV L.10.Vr\. t-'IC.l..l'-,..,

Bent turbine wheel

Oil leaks due to worn piston ring and insert

0 0

Improperly mounted turbine housing

0 0 0 0

Foreign substances deposited on front core of intercooler

Damaged oil seals due to clogged oil return pipe Improperly mounted compressor housing

0 0

Improperly mounted piston ring Unsmooth sliding of internal parts due to clogged lubrication oil pipe and eyebolt

(/)

Q) ......

0 0 0

Clogged air cleaner element

Remarks

,._

0 0 0 0

Air cleaner

lntercooler

·-g_

E::I

w aS 3: E w

Possible causes

(/)

-�

0 0

Deformed front pipe, muffler, tail pipe Improperly mounted front pipe, muffler, tail pipe

Gr 11

Defective head gasket

0 0

Worn valve and valve seat and deposited carbon

(-\ ,_)

Gr 11

Sagging valve spring

Gr 11

Incorrect valve clearance

0 0

Worn or damaged piston ring Worn or damaged piston ring groove of piston Malfunctioning cooling equipment

Gr 11

Gr 11 Gr 11 Gr 14

(' ,_)

Excessive engine oil

0 0

Gr 12

Seizure of major moving parts

Gr 11

Uneven or excessive fuel injection

(' ,_)

Gr 13

15-9

N-VEHI LE INSPECTI

DJUST ENT

1. Inspection of Dust Indicator Service standards

â&#x20AC;˘ Before checking the dust indicator 1, clean or replace the air cleaner element. â&#x20AC;˘ Start the engine, and cover the inlet of the air cleaner through use of a wooden block B in such a way that the negative pressure of the dust indicator 1 will have the nominal value and check that the mechanical type will show the red signal or the electric type will light the warning lamp. If there is anything wrong in operation, replace defective parts.

2 Air cleaner 18274

18275

15-10

A: Negative pressure gauge

15-11

NER <FH

[I]

5 1

18276

<FHG Double Element Type> 4 \

18277

<FWG>

18278

• Disassembly sequence 1 Clamp

2 Baffle

3 Dust cup 4 O-ring 5 Nut gasket <FHG>

Bolt gasket <FWG> 6 Element

NOTE

7 Nut gasket <FHG double element type> 8 Safety element <FHG double element type> 9 Dust indicator 10 Air cleaner body 0: Non-reusable part

Do not disassemble the safety element 8 except when it need be replaced.

• Reassembly sequence Reverse the order of disassembly.

15-12

15 Service standards Maintenance item

Location 9

Standard value

Negative pressure for operation of dust indicator

6.23 ± 0.57 kPa {635 ± 58 mmH20}

Limit -

Remedy Replace

� Sealant

♦ Service procedure

W Dust cup

Reassemble the dust cup 3 with the arrow mark A toward the inlet B.

6 Element [Cleaning] • Blow compressed air 685 kPa {7 kg/cm2} or less from inside the ele ment 6. • Blow the compressed air, working along the creases of filter paper of the element 6 up and down throughout the element.

CAUTION 13996

• Do not strike the element 6 to loosen dust. • Do not blow the air from outside the element 6. [Inspection] • Put a light inside the element 6. • If the filter paper is broken or partially thin, or if the packing on the top of the element 6 is broken, replace the element. • If the dust deposited on the element 6 is wet with oil smoke or soot, re place the element irrespective of the replacement intervals.

13997

15-13

IR CLE NER <FH

W Inspection of dust indicator Petiorm the following checks. If there is anything wrong, replace the dust indicator. <Mechanical type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check whether the red signal appears.

9 18281

<Electric type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check that there is continuity between terminals 1 1 and 12 • Check that when there is no negative pressure applied to the dust indi cator 9, there is no continuity between the terminals (1 and 1

9 18282

-----

---r

18280

15-14

1 •

AIR LEANER< <Single Element Type> <Type A>

�

\5 18283

\ 1

2 18284

18285

18286

• Disassembly sequence 1 Clip <Type B> 2 Wing nut <Type B> 3 Cover <Type B> 4 Gasket <Type B> 5 Nut gasket 6 Element 7 Nut gasket <Double element type>

NOTE

8 9 10 11

Safety element <Double element type> Dust indicator Vacuator valve Air cleaner body

0: Non-reusable part

Do not disassemble the safety element 8 except when it need be replaced.

• Reassembly sequence Reverse the order of disassembly.

15-16

15 Service standards Location 9

Maintenance item

Standard value

Negative pressure for operation of dust indicator

6.23 ± 0.57 kPa {635 ± 58 mmH20}

Limit -

Remedy Replace

� Sealant

♦ Service procedure

[I) Element

[Cleaning] • Blow compressed air 685 kPa {7 kg/cm2 } or less from inside the ele ment 6. • Blow the compressed air, working along the creases of filter paper of the element 6 up and down throughout the element.

CAUTION •

...., ___ ... -.a.-:1,,_ ..,.__ -1.-.......,.._��+ C. .. ,.., 1�,...,..,.. .... rl 1 -�·

UV IIVl .:::,u 1n.c UIC CICIIICIU V LU ,uv,;;, ... 11 ......... �.

• Do not blow the air from outside the element 6. [Inspection] • Put a light inside the element 6. • If the filter paper is broken or partially thin, or if the packing on the top of the element 6 is broken, replace the element. • If the dust deposited on the element 6 is wet with oil smoke or soot, re place the element irrespective of the replacement intervals.

13997

[fil Inspection of dust indicator Perform the following checks. If there is anything wrong, replace the dust indicator. <Mechanical type> • Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check whether the red signal appears.

9 18281

15-17

AIR LEANER<

> <Electric type> â&#x20AC;˘ Mount a hand vacuum pump A on the dust indicator 9 and apply the standard operating negative pressure to check that there is continuity between terminals and â&#x20AC;˘ Check that when there is no negative pressure applied to the dust indiÂ cator 9, there is no continuity between the terminals (1) and (gJ_

9 18282

18280

15-18

NER<

ridge> • Disassembly sequence 1 Clamp

2 Air cleaner 3 Dust indicator • Reassembly sequence Reverse the order of removal.

18287

Service standards

� Sealant

♦ Service procedure []] Cleaning air cleaner [Cleaning] Blow compressed air 685 kPa {7 kg/cm2} or less from inside the air clean er 2, working along the creases of filter paper up and down to clean the air cleaner.

CAUTION

18288

• Do not strike the element and do not blow the air from the suction portion. • Make sure that the loosened dust is not blown into the element

[fil Inspection of dust indicator • Mount a hand vacuum pump A on the dust indicator and apply the stan dard operating negative pressure to check whether the red signal ap pears.

18281

15-19

ER <T048, T04E (6 16-PT)>

TURB

• If the red signal does not appear, replace the dust indicator 3. �---------------------, • Removal sequence 1 2 3 4 5

Eyebolt Oil inlet pipe Oil return pipe Nut Turbocharger assembly [D P.15-22 6 Gasket

�1 5

*: Exhaust manifold [I) P.15-63, 64 0: Non-reusable part 2

• Installation sequence Reverse the order of removal.

18289

0 Tightening torque

Unit: N · m {kgf · m} Remarks

� Lubricant

♦ Service procedure

[fil Installation of turbocharger assembly

When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18290

15-20

15-21

TURB

ER <T048, T04E (6D16-PT)>

Turbocharger Assembly

\ @

18291

• Operations before disassembly

rn P.15-24

• Disassembly sequence 1 Bolt 2 Lock plate < T04B> 3 Clamp 4 Turbine housing 5 Bolt 6 Clamp 7 Compressor housing 8 Center housing and rotating as sembly

9 Lock nut 10 Compressor wheel 11 Turbine wheel

12 Piston ring 13 Wheel shroud 14 Bolt 15 Back plate 16 Seal ring 17 Thrust collar

18 Thrust bearing

19 Piston ring

20 Retaining ring

21 Bearing 22 Retaining ring 23 Center housing 0: Non-reusable part

CAUTION&------------------------Carefully remove piston rings 12 and 19, as they are readily broken.

• Cleaning after disassembly P.15-24 • Reassembly sequence 23 ➔ 22 ➔ 21 -➔ 20 ➔ 17 ➔ 18 ➔ 19 -➔ 16 ➔ 15 ➔ 14 ➔ 13 1 2 -➔ 11

CAUTION

Do not widen the piston rings 12 and 19 more than necessary, as they are readily broken.

• Inspection after reassembly P.15-25

15-22

15 Service standards Maintenance item

Location

Unit: mm

Turbine wheel

Bearing journal outside diameter

Hub diameter

Back plate

Thrust collar

Center housing

Limit

Remedy

[10.156]

10.152 or more

Replace

Shaft bend

Piston ring mounting portion

Standard value (Basic diameter in [ ])

Groove width Groove diameter

O.Oi or less

[17.31]

17.25 or more

1.69

1.74 or less

[14.46]

14.40 or more

Play in radial direction

0.076 to 0.150

Play in thrust direction

0.025 to 0.076

T04B

11.652

11.658 or less

T04E

11.672

11.684 or less

Seal bore inside diameter

[12.687]

12.712 or less

1.640

1 .659 or less

[10.35]

10.29 or more 4.44 or less

Seal land height

Piston ring mounting portion

Groove width

Thrust bearing mounting portion

Groove width

4.43

Groove diameter

[9.53]

9.40 or more

Groove diameier

Inside diameter

[6.358]

6.363 or less

Bearing inserting portion inside diameter

[15.800]

15.806 or less

Seal bore inside diameter

[18.03]

18.06 or less

0 Tightening torque Location

Replace

Unit: N · m {kgf · m} Tightening torque

T04B

18 to 21 {"1.85 to 2.19}

Remarks ·-

T04E

20 to 22 {2.07 to 2.29}

16 to 19 {1.67 to 1.89}

2.1 to 2.3 {0.21 to 0.23}

After tightening, turn down 90 ° C to 110 ° C further from that position.

Parts to be tightened

Bolt (for mounting turbine housing)

Bolt (for mounting compressor housing)

Bolt (for mounting back plate)

Replace

Lock nut (for mounting compressor wheel)

12 to 14 {1.26 to 1.45}

�\ Lubricant Location

Specified lubricant

Points of application

Apply to threads and bearing surface of bolt 1 Apply to threaded portion of bolt 5, 14 11, 12, Apply to all of the parts 17 to 22

Quantity

MOLYKOTE

As required

LOCTITE

As required

Engine oil

As required

15-23

ER <T048, T04E (6D16-PT)>

TURB � Special tools

Application

Part No.

Tool name and shape

Location T-handle

801059-0

Holding fixture

801053-0

Measuring element

801098-0

Inspection of play of turbine wheel in radial direction

12 20,22

Piston ring inserter

801050-0

Installation of piston ring

Retaining ring remover

801058-0

Removal and installation of retaining ring

Removal and installation of compressor wheel

Part numbers listed above are Honeywell part numbers.

♦ Service procedure • Operations before disassembly Make alignment marks A on the turbine housing 4, compressor housing 7 and center housing rotating assembly 8.

18292

• Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace. • Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

15-24

15 • Scrape off deposits. B : Plastic scraper or stiff brush

1=)

• Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly ( 1) Manually rotate the compressor wheel 10 and turbine 11 to check whether they rotate smoothly.

183581

(2) Play of turbine wheel in radial direction • Mount the I.&] Probe to the dial indicator A and insert it from the oil outlet and press it against the shaft of the turbine wheel 11 at right angles. • Move the shaft of the turbine wheel 11 up and down by both hands to measure the play in the radial direction. • If the reading is in excess of the limit, replace the bearing 21.

t 21

18294

(3) Play of turbine wheel in thrust direction • Set the dial indicator A on the end of the turbine wheel 11 and move the shaft of the turbine wheel in the axial direction to measure the play. • If the reading exceeds the limit, worn or defective back plate 15, thrust collar 17 and thrust bearing 18 are suspected. Replace.

17 18295

15-25

48, T04E (6D16-PT )> G] Turbine housing

TURB

[Removal] A: Rubber hammer

CAUTION&--------------

18296

• While using care to prevent damage to the turbine housing 4, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the turbine wheel are readily bent, use care to make sure that they do not hit the turbine housing 4. [Installation] • Apply the MOLYKOTE to the threads and bearing surface of the bolt 1 , partially tighten the bolt, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque. • Bend the lock plate 2 at two places against the bolts 1. <T04B>

CAUTION_&--------------

Use care to prevent damage to the blades of the turbine wheel 11.

18297

[zJ Compressor housing [Removal]

A: Rubber hammer

CAUTION.&_-------------

18298

• While using care to prevent damage to the compressor housing 7, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 1 Oare readily bent, use care to make sure that they do not hit the compressor housing 7. [Installation] Place the center housing & rotating assembly 8 on the compressor hous ing 7, line up the alignment marks made before disassembly, and tighten the bolt 1 to the specified torque.

18299

ffQj Compressor wheel [Removal] • Hold the �a Holding Fixture in a vice, and slowly insert the center housing & rotating assembly 8. • Using the 1:&]b T-handle, remove the lock nut 9 and slowly withdraw the compressor wheel 10 upward.

CAUTION_&-------------Use care to prevent bending the shaft of the turbine wheel 11.

18300

15-26

15 [Installation] • Hold the shaft of the turbine wheel 11 and center housing 23 by hand, and slowly insert them into the �a Holding Fixture.

CAUTION&.--------------

• When they are inserted, use care to prevent damage to the blades of the turbine wheel 11. • Do not release the shaft before insertion, as the turbine wheel 11 falls down. 18301 • Hold the lga Holding Fixture in a vice and slowly insert the compressor wheel 10. • Using the �b T-handle, tighten the lock nut 9 to the specified torque, and then turn it down 90 ° C to 110 ° C further from that position.

CAUTION&.------------Use care to prevent bending the shaft of the turbine wheel 11.

183021 [1] � Turbine wheel, wheel shroud [Removal] Place the back plate 15 side of the center housing 23 on the compressor housing 7 removed beforehand, and remove the turbine wheel 11 and wheel shroud 13.

11 13 15

""'1

18303 [Installation] After installation, lightly rotate the turbine wheel 11 by hand to check whether it continues to rotate. If it does not rotate lightly, re-perform the disassembly and reassembly procedures.

18304 [Inspection]

(1) Bend of shaft • Using the dial indicator, measure at the illustrated position. • If the reading exceeds limit, replace the turbine wheel 11.

13655

15-27

TURB CHAR ER <T04B, T04E (6D16-PT)> (2) Outside diameters of journal and hub 11

If any readings exceeds of the limit, replace the turbine wheel 11. A: Journal B:Hub

A-,__-� 18305

(3) Width and outside diameter of piston ring groove

If any reading exceeds of the limit, replace the turbine wheel 11. A: Width B: Outside diameter

183061

(g] Installation of piston ring 11

Insert the� Piston Ring Inserter into the turbine wheel 11 and install the piston ring 12.

__--12

18307

�Backplate [Installation] Slowly install the back plate 15 on the center housing 23, while lining up the alignment marks made before disassembly, and tighten the bolt 14 to the specified torque.

[Inspection] • Measure the seal land height A and seal bore inside diameter B of the back plate 15. • If any reading exceeds the limit, replace the back plate 15.

18309

15-28

15 [!] Piston ring groove and groove diameter of thrust collar and 17

thrust bearing groove width, groove diameter and bore inside di ameter

If any reading exceeds the limit, replace the thrust collar.

18311

A: Piston ring groove B: Thrust bearing groove C : Groove width D: Groove diameter E: Bore inside diameter � Installation of thrust bearing Install the thrust bearing 18 on the thrust collar 17 with the oil groove A toward the center housing 23, and insert it onto the positioning pins B of the center housing.

183121

� � Retaining ring

20,22

[Removal] �: Retaining Ring Remover

CAUTION&------------

When the retaining rings 20 and 22 are removed, hold your hand over the rings to make sure that they do not bounce out.

18313

[Installation] Install the retaining rings 20 and 22 securely in the groove of the center housing.

20,22

CAUTIONL:h-------------

When the retaining rings 20 and 22 are installed, hold your hand over the rings to make sure that they do not bounce out.

18313

� Check the bearing inserting portion inside diameter and seal bore diameter of the center housing.

If any reading exceeds the limit, replace the center housing 23. A: Bearing inserting portion inside diameter B : Seal bore diameter

18314

15-29

ER <T04E (6 16-TL), TBP4>

TURB

• Removal sequence

04----®

Eyebolt Oil inlet pipe Oil return pipe Nut Turbocharger assembly CO P.15-32 6 Gasket 1 2 3 4 5

*: Exhaust manifold CO P.15-63, 64 0 : Non-reusable part • Installation sequence

Reverse the order of removal.

18387

0 Tightening torque

Unit: N · m {kgf · m}

� Lubricant

♦ Service procedure

W Installation of turbocharger assembly When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18388

15-30

TURB

ER <T04E (6D16-TL), TBP4>

Turbocharger Assembly 0 12

021

18315

â&#x20AC;˘ Operations before disassembly Cl] P.15-34 â&#x20AC;˘ Disassembly sequence

1 Hose clamp

2 Hose

3 Retaining ring 4 Nut

5 Nut 6 Actuator assembly 7 Rod end 8 Bolt 9 Bracket 10 Bolt 11 Exhaust coupler 12 Gasket 13 Bolt

14 Clamp 15 Turbine housing 16 Bolt 17 Clamp

29 Thrust collar

18 Compressor housing 19 O-ring 20 Center housing & rotating

30 Thrust bearing 31 Piston ring 32 Retaining ring 33 Bearing 34 Retaining ring 35 Center housing

assembly 21 Lock nut

22 Compressor wheel

23 Turbine wheel 24 Piston ring

25 Wheel shroud

CAUTION Carefully remove the piston rings 24 and 31, as they are readily broken.

15-32

26 Bolt 27 Back plate 28 Seal ring

0 : Non-reusable part

15 • Cleaning after disassembly rn P.15-35 • Reassembly sequence 35 ➔ 34 ➔ 33 ➔ 32 ➔ 29 ·➔ 30 ➔ 31 ➔ 28 ➔ 27 ➔ 26 --

]- --+ 22 -➔ 21 ➔ 20 ·➔ 19 ➔ 18 ➔ 17 ➔ 16 24 ➔ 23 --

l--

➔ 15 ➔ 14 -➔ 13 -➔ 12 ➔ 11 ➔ 10 ➔ 9 -➔ 8 ➔

s➔4➔5 ➔1➔3➔2 ➔1

CAUTION&_-------------------------Do not widen the piston rings 24 and 31 more than necessary, as they are readily broken. • Inspection after reassembly Cl] P.15-35

Service standards Location

Unit: mm Standard value (Basic diameter in [ ])

Maintenance item

Actuator assembly set pressure

Turbine wheel

83 to 90 kPa {625 io 675 111111Hy}

[17.3 1]

17.25 or more

1.69

1.74 or less

[14.46]

14.40 or more

Play in radial direction

0.076 to 0.150

Check

Play in thrust direction

0.025 to 0.076 11.672

11.658 or less

Replace

[12.687)

12.712 or less

Groove width

1.640

1.659 or less

Groove diameter

[10.35]

10.29 or more

4.43

4.44 or less

[9.53]

9.40 or more

Inside diameter

[6.358]

6.363 or less

Bearing inserting portion inside diameter

[15.800]

15.806 or less

Seal bore inside diameter

[18.03]

18.06 or less

Groove

Seal land height

Piston ring mounting portion

Thrust bearing mounting Groove portion width Groove diameter Center housing

Replace

width

Seal bore inside diameter

·-i

0.01 or less

Groove diameter

Thrust collar

..-.1:.

Piston ring mounting portion

/'"\UJU;:)l

10.152 or more

Hub diameter

Back plate

Remedy

[10.156]

Bearing journal outside diameter Shaft bend

Limit

Replace

15-33

Tightening torque

Unit: N · m {kgf · m}

4 5 8 10 13 16 21

Remarks

T ightening torque

Parts to be tightened

Location

Nut (for mounting actuator assembly)

5.6 to 7.8 {0.57 to 0.80}

Nut (for mounting rod end)

5.6 to 6.8 {0.57 to 0. 70}

Bolt (for mounting bracket)

20 to 22 {2.07 to 2.29}

Bolt (for mounting exhaust coupler)

20 to 22 {2.07 to 2.29}

Bolt (for mounting clamp)

20 to 22 {2.07 to 2.29}

Bolt (for mounting clamp)

16 to 19 {1.67 to 1.89}

Lock nut (for mounting compressor wheel)

2.1 to 2.3 {0.21 to 0.23}

Bolt (for mounting back plate)

12 to 14 {1 .26 to 1 .45}

After tightening, turn down 90 ° C to 110 ° C further from that position.

� Lubricant Specified lubricant

Points of application

Location

13 16,26

Quantity A - -�- --· -�---- -• I

Apply to threads and bearing surfacA of holt

1\,1()1 Vk'nT;:::

n.::, I t:LfUII t:U

Appiy to threaded portion of bolt

LOCTITE

As required

Engine oil

As required

19, 23, Apply to all of the parts. 24, 29 to 34

� Special tools Location

Tool name and shape

Part No.

Application

T-handle

801059-0

Holding fixture

801053-0

Measuring element

801098-0

Inspection of play of turbine wheel in radial direction

Piston ring inserter

801050-0

Installation of piston ring

Retaining ring remover

801058-0

Removal and installation of retaining ring

32,34

Removal and installation of compressor wheel

Part numbers listed above are Honeywell part numbers.

♦ Service procedure • Operations before disassembly

Make alignment mark A on the turbine housing 15, compressor housing

18 and center housing & rotating assembly 20.

\ 20

15-34

18316

15 • Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace.

CAUTION&-------------

Do not immerse the actuator assembly 6 in the solvent. Clean it with a cloth dipped in kerosene.

• Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

136281

• Take out the parts from the solvent and blow compressed air A against them.

• Scrape off deposits. B: Plastic scraper or stiff brush • Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly (1) Manually rotate the compressor wheel 22 and turbine wheel 23 to check whether they rotate smoothly.

18358

15-35

TURB

ER <T04E (6 16-TL), TBP4> (2) Play of turbine wheel in radial direction • Mount the � Measuring Element to the dial gauge A and insert it from the oil outlet and press it against the shaft of the turbine wheel 23 at right angles. • Move the shaft of the turbine wheel 23 up and down by both hands to measure the play in the radial direction. • If the reading exceeds the limit, replace the bearing 33.

18317

(3) Play of turbine wheel in thrust direction • Set the dial gauge A on the end of the turbine wheel 23 and move the shaft of the turbine wheel in the axial direction to measure the play. • If the reading exceeds the limit, worn or defective back plate 27, thrust collar 29 and thrust bearing 30 are suspected. Replace.

A 29

18318

• Set the dial indicator A on the end of the rod end 7. (In this case, set the scale of the dial indicator to 0.) • Extend the rod end 0.38 mm by use of the external air B.) (The scale of the dial indicator A is 0.38 mm.) • With the scale of the dial indicator A at 0.38 mm, read the value of the pressure gauge C, and check to ensure that the reading is be tween 83 and 90 kPa {625 to 675 mmHg}.

---c

(4) Measurement of operating pressure of actuator assembly

Q -�---

(5) Adjustment of operating pressure of actuator assembly • If the reading of the pressure gauge C is not between 83 and 90 kPa {625 to 675 mmHg}, remove the retaining ring 3, loosen the nut 5, and adjust the length of the rod end 7. Rod end length adjusting direction Rod end extending direction ➔ Reduces the pressure. Rod end retracting direction ➔ Increases the pressure.

CAUTION&------------

18325

15-36

When the rod end length is adjusted, if the piston assembly D is rotated, damage to the diaphragm in the actuator assembly 6 will result. Secure the piston assembly through use of a vice, pliers, etc. to make sure that it is not rotated.

15 []] Air-tightness check on actuator assembly Slowly apply the air pressure A to the actuator assembly 6 to check that there are no air leaks when the air pressure is 87 kPa {650 mm Hg}. If there are air leaks, replace the actuator assembly. B: Pressure gauge

18366

� Turbine housing [Removal] A: Rubber hammer

CAUTION&--------------

'�,

15 183191

• While using care to prevent damage to the turbine housing 15, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the turbine wheel 23 are readily bent, use care to make sure that they do not hit the turbine housing -is.

[Installation] Apply MOLYKOTE to the threads and bearing surface of bolt 13, partially tighten the bolt, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque.

CAUTION&_-------------Use care to prevent damage to the blades of the turbine wheel 23.

18320

� Compressor housing [Removal] A: Rubber hammer

CAUTION

18321

• While using care to prevent damage to the compressor 18, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 22 are readily bent, use care to make sure that they do not hit the compressor housing 18. [Installation] • Place the center housing & rotating assembly 20 on the compressor housing 18, line up the alignment marks made before disassembly, and tighten the bolt 16 to the specified torque.

18322

15-37

ER <T04E (6D16-TL), TBP4>

TURB

� Compressor wheel [Removal] • Hold the �a Holding Fixture in a vice, and slowly insert the center housing & rotating assembiy 20. • Using the �b T-handle, remove the lock nut 21 and slowly withdraw the compressor wheel 22 upward.

CAUTION&------------- Use care to prevent bending the shaft of the turbine wheel 23.

18300

[Installation] • Hold the shaft of the turbine wheel 23 and center housing 35 by hand, and slowly insert them into the �a Holding Fixture.

CAUTION&--------------

• When they are inserted, use care to prevent damage to the blades of the turbine wheel 23. • Do not release the shaft before insertion, as the turbine wheel 23 falls down.

-�a 18301

• Hold the�a Holding Fixture in a vice and slowly insert the compressor wheel 22. • Using the �b T-handle, tighten the lock nut 21 to the specified torque, and then turn it down 90 ° C to 110 ° C further from that position.

CAUTION&-------------Use care to prevent bending the shaft of the turbine wheel 23.

� � Turbine wheel, wheel shroud [Removal] Place the back plate 27 of the center housing 35 on the compressor hous ing 18 removed beforehand, and remove the turbine wheel 23 and wheel shroud 25.

18303

[Installation] After installation, lightly rotate the turbine wheel 23 by hand to check whether it continues to rotate. If it does not rotate lightly, re-perform the disassembly and reassembly procedures.

18304

15-38

15 [Inspection] (1) Bend of shaft • Using the dial indicator, measure at the illustrated position. • If the reading exceeds the limit, replace the turbine wheel 23.

13655

(2) Outside diameters of journal and hub If any reading exceeds the limit, replace the turbine wheel 23.

A: Journal B: Hub

18305

(3) Width and outside diameter of piston ring groove

If any reading exceeds the limit, replace the turbine wheel 23.

A:Width

B : Outside diameter

18306

� Installation of piston ring 23

Insert the�] Piston Ring Inserter into the turbine wheel 23 and install the piston ring 24.

-----24

·t8307

�Backplate [Installation] Slowly install the back plate 27 on the center housing 35, while lining up the alignment marks made before disassembly, and tighten the bolt 26 to the specified torque.

15-39

TURB

ER <T04E (6D16-TL), TBP4> [Inspection] • Measure the seal land height A and seal bore inside diameter B of the back plate 27. • If any reading exceeds the limit, replace the back p!ate 27.

18309

� Piston ring groove and groove diameter of thrust collar and thrust bearing groove width, groove diameter and bore inside di ameter If any reading exceeds the limit, replace the thrust collar 29.

18311

A: Piston ring groove B: Thrust bearing groove C: Groove width D: Groove dla,neter E: Bore inside diameter

@Q] Installation of thrust bearing A

Install the thrust bearing 30 on the thrust collar 29 with the oil groove A toward the center housing 35, and insert it onto the positioning pins B of the center housing.

18312

� � Retaining ring

32,34

[Removal] �: Retaining Ring Remover

CAUTION&_-------------

When the retaining rings 32 and 34 are removed, hold your hand over the rings to make sure that they do not bounce out.

18313

[Installation] Install the retaining rings 32 and 34 securely in the groove of the center housing.

32,34

CAUTION,&.-------------

When the retaining rings 32 and 34 are installed, hold your hand over the rings to make sure that they do not bounce out.

18313

15-40

15 ďż˝ Check the bearing inserting portion inside diameter and seal bore diameter of the center housing.

If any reading exceeds the limit, replace the center housing 35. A: Bearing inserting portion inside diameter B : Seal bore diameter

18314

15-41

ER <TF07>

TURB

• Removal sequence 01

1 Eyebolt 2 Oil inlet pipe

3 Oil return pipe 4 Nut 5 Turbocharger assembly [[) P.15-44 6 Gasket

*: Exhaust manifold CO P.15-63, 64 0: Non-reusable part • Installation sequence Reverse the order of removal.

i8389

0 Tightening torque

Unit: N · m {kgf · m}

� Lubricant

♦ Service procedure

W Installation of turbocharger assembly

When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18390

15-42

15-43

ER <TF07>

TURB

Turbocharger Assembly

• Operations before disassembly [_[] P.15-45 • Disassembly sequence 1 Bolt 2 Lock plate 3 Turbine housing 4 Snap ring 5 Compressor cover 6 0-ring 7 Wheel and bearing housing assembly 8 Lock nut

9 Compressor wheel

Snap ring Insert Piston ring Oil deflector Thrust sleeve Thrust bearing Thrust ring 17 Shaft & turbine wheel

10 11 12 13 14 15 16

18 19 20 21 22

Turbine back plate Piston ring Bearing 0-ring Bearing housing

0: Non-reusable part

CAUTION,&-------------------------Carefully remove piston rings 12 and 19, as they are readily broken.

• Cleaning after disassembly [[J P.15-46 • Reassembly sequence 22➔21➔20➔1 8 19➔1 7

----16➔15 14 -➔ 13➔12 ➔ 11

CAUTION

-�10➔9➔8➔7➔6➔5➔4➔3➔2➔1

Do not widen the piston rings 12 and 19 more than necessary, as they are readily broken.

• Inspection after reassembly P.1s-46

15-44

15 Service standards

Unit: mm Maintenance item

Location

Standard value

Limit

Remedy Check

Clearance between shaft & turbine wheel and turbine housing

0.55 to 0.65

Clearance between open ends of piston ring (Measure the clearance of a new piston ring.)

0.05 to 0.25

Shaft & turbine wheel

Replace insert

9.9962

Replace

0.D15

Replace

3, 17

17,18 20

Outside diameter of bearing journal Bend of shaft End play

0.057 to 0.103

Clearance between shaft & turbine wheel back surface and turbine back plate Bearing

Inside diameter Outside diameter Length

Bearing inserting portion inside diameter of bearing housing

0.677to 1.123

Check Check

10.0328

Replace

16.901 11.84 17.006

Replace

Unit· N • m {kgf · m}

Tightening torque

Parts to be tightened

Location

12to 14{1.2to 1.4}

Bolt (for mounting lock plate)

Lock nut (for mounting compressor wheel)

18 to 21{1.85 to 2.19}

Remarks -

Lubricant

Location

Points of application

Specified lubricant

Quantity

Apply to threads of bolt

MOLYKOTE

As required

Apply to threads of lock nut

MOLYKOTE

As required

Apply to all of the parts.

Engine oil

As required

6, 12, 14 to 17, 19 to 21

♦ Service procedure • Operations before disassembly

Make alignment marks on the turbine housing 3, compressor cover 5 and wheel & bearing housing assembly 7. 7 3

18324

15-45

TURB CHAR ER <TF07> • Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace. • Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI C LEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

18359

• Scrape off deposits. B : Plastic scraper or stiff brush • Re-immerse in the solvent. • Blow compressed air A.

13630

• Inspection after reassembly Manually rotate the compressor wheel 9 and turbine wheel 17 to check whether they rotate smoothly.

18360

15-46

15 W Turbine housing [Removal]

A: Rubber hammer

CAUTION&--------------

• While using care to prevent damage to the turbine housing 3, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the shaft & turbine wheel 17 are readily bent, use care to make sure that they do not hit the turbine housing 3. [Installation] Apply MOLYKOTE to the threaded portion of the bolt 1, line up the align ment marks made before disassembly, and then tighten the bolt to the specified torque.

CAUTION6--------------

Use care to prevent damage to the blades of the shaft & turbine wheel 17.

182971

[I) ffz] Measurement of clearance between turbine housing and shaft & turbine wheel

If the reading exceeds the nominal value, disassemble and check to lo cate the cause.

18326

[� Installation of snap ring Line up the alignment marks made before disassembly and install the snap ring 4 as shown.

A: Tapered surface

A�

CAUTION 18327

When the snap ring 4 is installed, hold it by hand to make sure that it does not bounce out. Removal of compressor cover

A: Rubber hammer

CAUTION

• While using care to prevent damage to the compressor cover 5, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 9 are readily bent, use care to make sure that they do not hit the compressor cover 5.

A 18328

15-47

TURB

ER <TF07> []] Compressor wheel [Removal] Hold the turbine housing 3 in a vice, and install the wheel & bearing hous ing assembly 7.

CAUTION&_------------ Since the blades of the shaft & turbine wheel 17 are readily bent, make sure that they do not hit the turbine housing 3.

18329

• While holding down the boss on the shaft & turbine wheel 17, remove the lock nut 8.

�8

-9

18330

[Installation] Hold the turbine housing 3 in a vice and install the temporarily assembly wheel & bearing housing assembly 7.

CAUTION&_------------ Since the blades of the shaft & turbine wheel 17 are readily bent, make sure that they do not hit the turbine housing 3.

18329

• While holding down the boss on the shaft & turbine wheel 17, apply MOLYKOTE to the threaded portion of the lock nut 8, and tighten the lock nut to the specified torque.

[IQ] Snap ring [Removal]

CAUTION&_-------------

When the snap ring 1 O is removed, hold it by hand to make sure that it does not bounce out.

18332

15-48

15 [Installation] • Install the snap ring 1 O in the illustration direction in the bearing housing 22.

10 A 22 ��

A: Tapered surface

CAUTION_&-------------

When the snap ring 1 O is installed, hold it by hand to make sure that it does not bounce out.

• Install the snap ring 1 O securely in the groove of the bearing housing 22. B: Hammer C: Screwdriver

CAUTION_&--------------

Use care to make sure that the plain screwdriver C does not hit the

136471

[I"j] Insert [Removal] A: Screwdriver

[Installation] Install the oil deflector 13 in the illustrated direction in the bearing housing 22. 22

� Measurement of clearance between open ends of piston ring

�A \ 12

• Mount a new piston ring 12 in the insert 11. • Measure the clearance A between the open ends of the piston ring. • If the reading is out of the nominal value, replace the insert 11.

11 -12

13650

15-49

TURB CHAR ER <TF07> � ff§] Installation of thrust bearing, thrust ring �-15

Install the thrust bearing 15 and thrust ring 16 in such a way that they will be directed as shown.

�-------- 16

18336

[Izl Shaft & turbine wheel [Inspection] (1) Bend of shaft • Using the dial indicator, measure at the illustrated position. • If the reading exceeds the limit, replace the shaft & turbine wheel 17.

13655

(2) Outside diameter of journal 17

If the reading exceeds the limit, replace the shaft & turbine wheel 17.

13656

(3) Rough journal

If the journal is rough, repair by the following procedures. [Repair]

• Install the shaft & turbine wheel 17 on a lathe with both centers sup ported. • Lightly grind the journal through use of emery paper #400 and en

gine oil.

CAUTION&_------------After the journal has been ground, be sure to measure the out side diameter of the journal.

15-50

15 (4) End play

If the reading exceeds the nominal value, disassemble and check to locate the cause.

[!:zJ � Clearance

between shaft & turbine wheel back surface and turbine back plate

• Using two thickness gauges, measure the clearance at the end of blade. • If any reading exceeds the nominal value, disassemble and check to locate the cause.

@Q]

Inspection of bearing

• Measure at the illustrated position A: Outside diameter B : Inside diameter C: Length

• If any reading exceeds the limit, replace the bearing 20. 13657

� Inspection of bearing housing

• Measure the inside diameter of the bearing 20 mounting portion. • If the reading exceeds the limit, replace the bearing housing 22.

13658

15-51

INTER

LER <6D16-TL, 16-TLE> • Disassembly sequence 1 Clamp 2 Rubber hose 3 lntercooler • Reassembly sequence Reverse the order of disassembly.

Service standards kPa

0 Tightening torque

Unit: N · m {kgf · m} Remarks

♦ Service procedure

@] Inspection of intercooler Put a cap A on either of the air ports of the intercooler 3 and connect a hose to the other, immerse the intercooler 3 in a water tank, and apply the standard pressure from the hose side to check for air leaks. If there are air leaks, replace the intercooler.

18349

15-52

15-53

LD <6D14, 16, 16-E>

2 18338

18337

• Disassembly sequence 1 2 3 4 5

Earth plate Coupler Gasket Air heater Gasket

6 Bolt 7 Intake manifold 0 : Non-reusable part

• Reassembly sequence Reverse the order of removal.

0 Tightening torque

Unit: N · m {kgf · m} Remarks

� Sealants Kinds manifold

15-54

ThreeBond 1207B

15 ♦ Service procedure [}] Installation of air heater

The air heater 4 should be installed with its arrow mark A directed toward the intake manifold 7.

18698

[zJ Installation of intake manifold q> 1.5

• The intake manifold is installed by use of either a seat gasket or seal ant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold on the cylinder head in less than three min utes after application of sealant A.

CAUTION/!\-------------------

• Thoroughly clean the sealant applying surface of the intake man ifold 7 beforehand. • When the intake manifold 7 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 6 was loosened, be sure to re apply sealant A to the intake manifold 7. • Do not start the engine in less than an hour after installation.

15-55

<6D14- 15-T, 16- 16-PT>

â&#x20AC;˘ Disassembly sequence 1 2 3 4 5

Rubber hose Earth plate <with air heater> Air inlet pipe Gasket Air heater <With air heater> Spacer <Without air heater> 6 Gasket 7 Bolt 8 Intake manifold

*: Turbocharger assembly [[] P.15-20 0 : Non-reusable part â&#x20AC;˘ Reassembly sequence Reverse the order of disassembly.

18340

18341

15-56

15 0 Tightening torque

Unit: N · m {kgf · m}

� Sealant

♦ Service procedure

W Installation of air heater or spacer

The air heater 5 or the spacer 5 should be installed with its arrow mark A directed toward the intake manifold 8.

A 5

18699

[!] Installation of intake manifold • The intake manifold 8 is installed by use of either a seat gasket or seal ant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 8. • Install the intake manifold 8 on the cylinder head in less than three min utes after application of sealant A. 18339

CAUTION&-------------

• Thoroughly clean the sealant applying surface of the intake man ifold 8 beforehand. • When the intake manifold 8 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 7 was loosened, be sure to re apply sealant A to the intake manifold 8. • Do not start the engine in less than an hour after installation.

15-57

LD <6D16-TL>

18342

• Disassembly sequence 1 Rubber hose 2 Overboost valve 3 Air inlet pipe 4 Air inlet pipe 5 Gasket 6 Spacer 7 Gasket

8 Bolt

9 Intake manifold *: Turbocharger assembly rn P.15-30 0: Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

0 Tightening torque

Unit: N · m {kgf · m} Remarks

Sealant ThreeBond 1207B

15-58

15 ♦ Service procedure

W Installation of spacer

The spacer 6 should be installed with its arrow mark A directed toward the intake manifold 9.

18699

$ 1.5

18339

W Installation of intake manifold • The intake manifold 9 is installed by use of either a seat gasket or seal ant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 9. • tn�t;:ill the intake manifold 9 on the cylinder head in less than three minutes after application of sealant A. ,-.. A I ITll"\t.l J.\ v.1-\U 11vn�-------==---------• Thoroughly clean the sealant applying surface of the intake man ifold 9 beforehand. • When the intake manifold 9 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 8 was loosened, be sure to re apply sealant A to the intake manifold 9. • Do not start the engine in less than an hour after installation.

15-59

<6D16-TLE>

IN *

2 0 \ 3

�7

®470711

• Disassembly sequence 1 2 3 4 5

Rubber hose Overboost valve Air inlet pipe Air inlet pipe Gasket

6 Bolt 7 Intake manifold

*: Turbocharger assembly

ClJ P.15-30 0 : Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

0 Tightening torque

Unit: N · m {kgf · m} Remarks

� Sealant ThreeBond 12078

15-60

15 ♦ Service procedure

[zJ Installation of intake manifold • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold 7 on the cylinder head in less than three min utes after application of sealant A.

CAUTION&_--------------

12256

15-61

EXHAUST

LD <6D14, 16, 16-E>

18343

18344

• Disassembly sequence 1 2 3 4

Nut Gasket Nut Exhaust manifold

5 Gasket *: Cylinder head

m Gr.11

O: Non-reusable part

• Reassembly sequence Reverse the order of disassembly.

0 Tightening torque

Unit: N · m {kgf · m} Remarks

♦ Service procedure

[!] Installation of gasket

Install the gasket 5 with the grommet fold-back portion A toward the cylin der head.

* 15-62

12259

EXHAUST MANIFOLD <6D14-T, 16-T, 16-PT, 16-TL, 16-TLE> • Disassembly sequence 1 Cover 2 Nut 3 Exhaust manifold 4 Gasket *: Cylinder head Gr.11 0 : Non-reusable part • Reassembly sequence Reverse the order of disassembly.

18346

0 Tightening torque

Unit: N · m {kgf · m}

Location 2

Nut

♦ Service procedure

[!] Installation of gasket

Install the gasket 4 with the grommet fold-back portion A toward the cylin der head.

7 12259

15-63

EXHAUST ANIFOLD <6D14- 16-T, 16-PT, 16-TL, 16-TLE> • Disassembly sequence 1 2 3 4 5

Front insulator Rear insulator Nut Exhaust manifold Gasket

*: Cylinder head CO Gr.11 0 : Non-reusable part • Reassembly sequence Reverse the order of disassembly.

18347

0 Tightening torque

Unit: N · m {kgf · m} Remarks

♦ Service procedure

[§]

Installation of gasket

Install the gasket 5 with the grommet fold-back portion A toward the cylin der head.

12259

15-64

I SPECIFICATIONS ........................................

54-2

STRUCTURE AND OPERATION 1. 2. 3. 4. 5. 6.

Circuit Diagram ................................................ Alternator ...................................................... Charging Circuit ................................................ Starter ......................................................... Preheating Circuit .............................................. Engine Starter Circuit ...........................................

�--1 ....+., 0-1 ........ ..,;,an:;;;Ly , •�•ay

1 .

•••••••••••••••••••••••••••••••••••••••••••••..••••

8. Automatic Stop System .........................................

TROUBLESHOOTING .....................................

54-4 54-7 54-16

54-18 54-21 54-22 54-23 54-24

54-32

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Preheater System ................................. 2. Inspection of Safety Relay ...................................... 3. Automatic Stop System .........................................

54-34 54-34 54-39

ALTERNATOR <24V-35A> ....................................................... 54-46 <24V-80A (with brush)> ........................................... 54-54 <12V-60A> ....................................................... 54-62 <24V-40A (with vacuum pump)> ................................... 54-70 <24V-40A (without vacuum pump)> ................................ 54-78 <24V-50A> ....................................................... 54-84 <24V-80A (brushless)> ............................................ 54-90 <24V-90A> 54-96 <12V-80A> ....................................................... 54-102

■

STARTER <24V-5kW> ....................................................... 54-108 <24V-6kW> ....................................................... 54-121 <12V-5kW> ....................................................... 54-132

PREHEATER CIRCUIT .................................... 54-146 ENGINE STARTER CIRCUIT ............................... 54-149 AUTOMATIC STOP SYSTEM • Shutdown ...................................................... 54-150 • Run-on ......................................................... 54-154

54-1

SPECIFI

Item Alternator

Specifications

Manufacturer

MITSUBISHI ELECTRIC CORP.

Vacuum pump

With brush Not provided

Provided

Brushless

Output (V-A)

5379

5386

24-35

6086

2386

24-

Manufacturer Model

12-

3186

0286

24-40

Magnet switch operating voltage

A4T4 A4T4 A4T4 A4T7 A4T7 A4TU 0379

0386

24-50

0399

M5T50179

0099 24-

16 or less

0199

0286

24-

M9T50071

24-6

24-5

Output (V-kW)

0299

MITSUBISHI ELECTRIC CORP.

M8T60073

M8T60071

I I

Not provided

A3TN A3TN A6T7 A2T3 A4TU A4T4 A4T4

Model

Starter

Alternator with built-in regulator, fan externally mounted type

Alternator with built-in regulator, fan internal contact type

Type

12-5

8 or less

(V)

Starter relay

Model

U1T35383

U1X15076

Exciting current

24-2.3

12-4

Closed magnetic voltage (V)

16 or less

8 or less

Opened magnetic voltage (V)

4 or less

3.5 or less

Allowable breaking voltage (V)

200

(V--A)

Intake air heater

Manufacturer Voltage - capacity

(V-kW)

Hiyoshi Denso 22-1.83

Fuse capacity (A) Heater relay

Manufacturer Model Voltage

(V-A)

54-2

11-1 .83

127

MITSUBISHI ELECTRIC CORP. U1T31382

current

Fuse capacity (A)

22-2.9

U1T31383

U1T31384

24-2.3 91

127

U1T11373 12-4

164

127

12-

54 - - ,-

Item Glow plug

Specifications

Type

Sheathed type

Voltage - current

23-3

(V-A) Glow relay

Model Voltage

U1T06670 current

24-2.3

(V-A) Fuse capacity (A) Safety relay Stop solenoid

127

Manufacturer Kind

Kimura Yoko

DENSO

Shut-down type

Run-on type Electromagnetic type

Type Solenoid relay

Manufacturer

Nikko Denki Shut-down type

Run-on type

24V

0-25000-5592

0-25000-6720

12V

0-25000-6361

0-25000-6990

Kind Model

R8T30175

R8T30174

Model

54-3

STRU TURE 1. Circuit Diagram <24V (Air Heater) Specification> 13

Wire symbol 0.85 f- Wire conductor sectional area (0.85 mm or more)

1 Starter switch 2 Heater relay 3 Air heater

4 Heater indicator

5 Battery 6 Battery relay 7 Tachometer sensor 8 Ammeter 9 Lamp switch 10 Tachometer 11 Fuse box

12 Safety relay 13 Alternator

14 Starter relay

15 Starter 16 Thermometer (for oil) 17

l"'\'l""\nr-linn â&#x20AC;˘ 11""-i+ Tho.-mn t IIVIIIIV VVIIUIII Ullll ďż˝

18 T hermometer (for c oolant) 19 Thermo sending unit Oil pressure gauge Oil pressure gauge unit Warning lamp Oil bypass alarm switch

20 21 22 23

B: Terminal 8 E: Terminal E l: Terminal L M: Terminal M P: Terminal P R: Terminal R S: Terminal S

SW: Terminal SW

18458

54-4

54 <24V (Glow Plug) Specification> 13

Wire symbol QJlli f-- Wire conductor sectional area (0.85 mm or more)

1 2 3 4

8 9 10 11 12 13 14 15 16

��,,

19 o.ssJ\..o�_�,.'' �

20 21 22 23

OB�

A +

B: Terminal B

'-+--+--0�.8�5--+' ,�'-+-�0�.B�___c::::::;::-i

E: Terminal E L: Terminal L M: Terminal M P: Terminal P R: Terminal R S: Terminal S SW: Terminal SW

�

7 60

Starter switch Glow relay Glow plug Glow indic ator Battery Battery relay Tachometer sensor Ammeter Lamp switch Tachometer Fuse box Safety relay Alternator Starter relay Starter Thermometer (for oil) Thermo sending unit Thermometer (for c oolant) J hermo sending unit Oil pressure gauge Oil pressure gauge unit Warning lamp Oil bypass alarm switch

18459

54-5

STRU TURE <12V S

cification>

1 Starter switch 2 Heater relay 3 Air heater

4 Heater indic ator 5 Battery 6 Battery switch 7 Tachometer sensor 8 Ammeter 9 Lamp switch 10 Tachometer 11 Fuse box 12 Hour meter 13 Alternator 14 Starter relay 15 Starter 16 Thermometer (for coolant) 17 Thermo sending unit 18 Oil pressure gauge 19 Oil pressure gauge unit 20 Warning lamp 21 Oil bypass alarm switch

8: Terminal B E: Terminal E L: Terminal L M: Terminal M R: Terminal R S: Terminal S SW: Terminal SW

8 2

1 18460

54-6

54 2. Alternator <24V-35A>

16742

1 Rectifier 2 Stator assembly

Rotor assembly Pulley Front bearing Front bracket

Fan Rear bracket Brush spring Regulator & brush holder 11 Brush 12 Rear bearing 7 8 9 10

B: Terminal B E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54-7

STRUCTURE

<24V-80A (with brush)>

R�

L� 2

7 10625

Rectifier Rotor assembly Stator assembly Fan 5 Pulley Front bearing

1 2 3 4

54-8

7 Front bracket

B: Terminal B

11 Rear bearing 12 Brush

R: Terminal R

8 Field coil 9 Rear bracket 10 Regulator

E: Terminal E L: Terminal L P: Terminal P

54 <12V-60A>

16743

1 Rectifier 2 Stator assembly

3 Rotor assembly 4 Pulley 5 Front bearing 6 Fan

7 Front bracket 8 Brush 9 Brush spring 10 Rear bracket 11 Regular & brush holder 12 Rear bearing

B: Terminal B E: Terminal E

L: Terminal L R: Terminal R

54-9

STRU TURE <24V-40A (with vacuum pump)>

8 7 09431

1 Rectifier 2 Rotor assembly 3 Stator assembly 4 Fan Pulley Front bearing

54-10

7 Front bracket

8 Field coil 9 Rear bracket

10 Regulator 11 Vacuum pump 12 Rear bearing

B: Terminal 8 E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54 <24V-40A (without vacuum pump), 12V-80A>

08644

1 Rectifier

2 Rotor assembly

Stator assembly

4 Fan

Pulley Front bearing

7 Front bracket

8 Field coil 9 Rear bracket 10 Regulator 11 Rear bearing

B: Terminal B

E: Terminal E L: Terminal L P: Terminal P

R: Terminal R

54-11

STRUCTURE

<24V-50A> 5 B

7 ÂŽ34192

1 2 3 4 5 6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

54-12

7 8 9 1O 11

Front bracket Field coil Rear bracket Regulator Rear bearing

A: Neutral point diode B: Terminal B E: Terminal E L: Terminal L A: Terminal R

54 <24V-80A (brushless), 90A>

R L

E 4

16744

1 Rectifier

Regulator 3 Stator assembly

Field coil 5 Fan

Pulley

7 Front bearing 8 Front bracket 9 Rotor assembly

10 Rear bracket

11 Rear bearing

A : Neutral point diode <90A> B: Terminal B E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54-13

STRU TURE • Alternator with neutral point diode

.-1

Effectiveness of alternator with neutral point diode The point where three stator coils A are coupled is called the neutral point C. Addition of two diodes D to the current alternator which uses six diodes makes it possible to provide a higher DC output than an alternator without neutral point diodes.

B: Alternator terminal B E: Alternator terminal E F: IC regulator L: Alternator terminal L

R E

R: Alternator terminal R

F 07033

Voltage o

"------+,..,...,...,,-------',..-,,-,,..,!----

Turning angle

07400

Variations in potential at neutral point, and operation of neutral point diode • The potential at the neutral point C varies up and down as shown with the neutral point DC voltage (one half of the out put voltage) as the center. When the alternator rotates at a very high speed, the peak values of the potential by far exceed the output voltage. (28V or more, OV or less) G: During high speed rotation H: During low speed rotation J: Neutral point voltage waveform K: Output voltage L: Mean voltage at neutral point M: Ground potential

In each of the voltage and potential conditions, the neutral point diode operates as described below. • When the neutral point voltage is more than OV and less than 28V, the six conventional diodes operate.

54-14

54 B

: --; _J

• When the neutral point voltage is more than 28V The positive side diode N conducts to add to the conventional DC output, so a higher DC voltage is output to each equipment.

R E

07034

t� I __...;.______.o

• When the neutral point voltage is less than OV The negative side diode P conducts, and the neutral point out put is supplied via the three conventional diodes.

: _! _j _J

R E

07035

54-15

STRU TURE

PERATI N

3. Charging Circuit

5 B R

L E

l 7 8

8 6

<Without charge lamp> 16739

1 2 3 4 5 6 7 8

Battery Battery relay Ammeter Fuse box Alternator Safety relay <Circuit without charge lamp> Charge lamp <Circuit with charge lamp> Starter switch

54-16

A: To starter relay terminal B B: Terminal 8 E: Terminal E L: Terminal L R: Terminal R

54 2

When engine is stationary

Position of starter switch 8: ON • To improve the performance of the alterna tor 5 in starting power generation at a low speed immediately after the engine has been started, current is set flowing to termi nal R. 1 ➔2➔8 <With charge 6 lamp> <Without charge lamp>

16740

-r

5 (R ➔ E) ➔ Earth � 6 (R ➔ L) ➔ 5 (L ➔ E) ➔ Earth

• In the circuit with A charge lamp 7, current flows as shown below.

1➔2➔8

-r

5 (R ➔ E) ➔ Earth � 7 ➔ 5 (L ➔ E) ➔ Earth

After engine has been started 2

Position of starter switch 8: ON • The alternator 5 starts generating power. • The output voltage at terminal B of the alter nator 5 becomes higher than the voltage of the battery 1. • The alternator 5 starts charging the battery

1. 5 (B) ➔ 4 ➔ 3 ➔ 8 ➔ 2 -➔ 1 8

16741

• In the case of the circuit with the charge lamp 7, the charge lamp goes out, as there is no potential difference between the voltage at terminal L of the alternator 5 and the battery voltage.

54-17

STRUCTURE

4. Starter <24V-6kW>

\ 9

18 17

15 14 13

18987

1 Rear bracket 2 Brush 3 Brush spring

4 Brush holder assembly 5 Magnet switch 6 Lever 7 Guide 8 Center bracket 9 Front bracket 10 Sleeve bearing 11 Stopper ring 12 Overrunning clutch 13 Gear bracket

54-18

14 Gearshaft

15 16 17 18 19 20 21 22

Gearshaft bearing Internal gear Rubber packing Front bearing Armature Yoke assembly Rear bearing Starter relay

B: Terminal B M: Terminal M S: Terminal S

4 <24V-5kW> A

B M 1

22 17 1 2 3 4 5 6

10 11 12 13 14 15 16 17 18

Rear bracket Brush Brush spring Brush holder assembly Magnet switch Ball 7 Lever 8 Front bracket 9 Spring

Pinion stopper Pinion Front bearing Overrunning clutch Washer Gearshaft assembly Internal gear assembly Planetary gear Packing

10739

19 20 21 22

Yoke assembly Armature assembly Packing Rear bearing

B: Terminal B M: Terminal M S: Terminal S

This starter uses planetary gear 17 in the reduction gear mechanism.

17 13501

54-19

STRU TURE <12V-5kW>

� SW (0.85-YL) L (0.8S-BY) ®26396

1 Rear bracket 2 Brush 3 Brush spring 4 Brush holder 5 Magnetic switch 6 Ball 7 Starter relay 8 Lever 9 Front bracket 10 Spring

11 Pinion stopper 12 Pinion 13 Front bearing 14 Overrunning clutch 15 Washer 16 Gear shaft 17 Internal gear assembly 18 Planetary gear assembly 19 Rubber packing 20 Yoke assembly

21 Armature assembly 22 Rubber packing 23 Rear bearing B: Terminal B L: Terminal L M: Terminal M S: Terminal S SW: Terminal SW

This starter uses planetary gear 18 for the reduction gear system.

18 ®26397

54-20

54 s.

Preheating Circuit

1 Starter switch 2 Battery relay 3 Battery 4 Heater relay 5 Heater indicator 6 Intake air heater

1 5

1 Starter switch

2 3 4 5 6

OFF HEAT ON

Battery relay Battery Heater relay Glow indicator Glow plug

STAR

18462

54-21

STRU TURE AND

6. Engine Starter Circuit

16757

1 Battery Battery relay Starter relay Starter Safety relay 6 Starter switch

2 3 4 5

54-22

54 7. Safety Relay T he safety relay detects the rotating speed of the alternator. When the rotating speed exceeds the reference value, the safety relay keeps the starter inoperative even if the starter switch is accidentally set to ON while the engine is running.

17530

P: Terminal P R: Terminal R L:Terminal L S: Terminal S E: Terminal E

L_�----t E-1 Alternator

2 Starter switch

r 1

17531

6 Safety relay 7 IC regulator

3 Battery switch

4 Battery 5 Starter relay

A: To starter terminal B

• When the starter switch 2 is set to ON, current flows from the starter relay 5 through terminal S of the safety relay 6 to terminal E, and contact P1 closes. • When rotation of the starter causes the engine to start running, pulses with a frequency of a tenth of the alternator speed are generated at terminal P of the alternator 1. • When the pulse frequency at terminal P of the alternator 1 exceeds the reference value, the continuity between terminals S and E is lost, and the starter remains inoperative even if the starter switch 2 is set to ON while the engine is running.

54-23

N 8. Automatic Stop System 1 Battery 2 Starter switch 3 Battery relay 4 Stop switch 5 Solenoid relay 6 Solenoid 7 Engine oil pressure switch 8 Stop lever 9 Injection pump governor 10 Water temperature sensor @: Engine stop signal @: Hydraulic pressure detection signal Solenoid drive signal @: Coolant temperature detection signal

ÂŠ:

5 10 9

18736

When the oil pressure becomes abnormal or when the coolant temperature abnormally rises while the engine is running, the automatic stop system automatically stops the engine. When anything wrong occurs in the oil pressure or coolant temperature, it is detected by the engine oil pressure switch 7 or water temperature sensor 10 which operates the solenoid relay 5. As a result, the solenoid 6 moves the stop lever 8 of the injection pump governor 9 in the direction A that the engine stops, thereby stopping the engine. The system comes in two types; the shutdown type and run-on type.

54-24

54 <Shutdown> 1

1 Solenoid relay 2 Alternator 3 Solenoid

�

4 Starter

5 Battery relay 6 Battery 7 Starter switch

8 Ammeter Stop switch Fuse box Engine oil pressure switch Coolant temperature sensor

9 10 11 12

4 11

Hi 5

6 ti

7 18737

• On normal condition, solenoid 3 is not energized and the stop lever A of the injector pump governor is at the drive side B to keep the engine in running condition. • When a trouble occurs, solenoid 3 is energized and pulls the stop lever A to the stop side C to stop the engine. 3

.... 18738

54-25

STRUCTURE

N Before engine starts • Position of starter switch 7: ON 6➔ 5

--r 7 (B ➔ BR) ➔ 5 (coil)➔ Earth

� 4 (B) ➔ 1 (B) ➔ 11 ➔ 1 (W) ➔ Earth

• Since no generated voltage from the alternator 2 is available at terminal A of the solenoid relay, the solenoid relay 1 remains inoperative, and no current is supplied to the solenoid 3. Therefore, the stop lever A of the injection pump governor stays at the position C where the engine can be started.

18739

18740

When engine starts • Position of starter switch 7: START

54-26

18741

When the engine is started, the generated voltage from the alternator 2 is applied to terminal A of the solenoid relay 1. At this point, the oil pres sure is still low. Therefore, the contact of the oil pressure switch 11 remains closed, and current flows to terminal W of the solenoid relay 1 to actuate the solenoid relay. In the solenoid relay, however, the voltage applied to terminal A is accumulated in the capacitor, so the current does not immediately flow to the operating circuit in the relay, thereby delaying the time the solenoid relay is actuated. During the period, the engine oil pressure rises, and the contact of the oil pressure switch opens to stop the supply of current to terminal W of the solenoid relay, making the solenoid relay completely inactive.

54 When engine is automatically stopped • When the oil pressure abnormally falls or the coolant temperature abnormally rises while the engine is running, engine oil pressure switch 11 or coolant temperature sensor (thermo switch) 12 turns on and cur rent flows as described below. 6 ➔ 5 -p 7 (8 ➔ BR) ➔ 5 (coil) ➔ Earth 4 (8) ➔ 1 (8) 11 ➔ 1 (W) ➔ Earth 4 4 12--1

-r

• At this point, the current from terminal A of the solenoid relay 1 is flow ing the internal circuit, the switch in the relay is activated and the cur rent flows as follows: 1 (8) ➔ Internal switch of the relay➔ 1 (C) ➔ 3 ➔ Earth

• As a result, solenoid 3 is activated and pulls the stop lever A in direction D to stop the engine. • Even after losing the generating voltage from the alternator 2, the inter nai capacitor of the soienoid reiay i keeps the soieriuiu 3 ir1 J.JOSitior,. 18742

18743

When engine is manually stopped

• Position of stop switch 9: ON Irrespective of the generating voltage of the alternator 2, current from stop switch 9 flows to the internal circuit via ST-terminal of the solenoid relay 1 to activate the internal switch of the relay, and the current flows as follows: 1 (8) ➔ Internal switch of the relay➔ 1 (C) ➔ 3 ➔ Earth

• As a result, engine is stopped in the same way as the automatic stop.

18744

54-27

STRU TURE <Run-On>

1 2 3 4 5 6 7 8

Solenoid relay Solenoid Stop switch Battery switch Battery Heater relay Starter switch Alternator 9 Ammeter 10 Engine oil pressure switch 11 Coolant temperature sensor

11 3

B: Terminal B C: Terminal C H: Terminal H S: Terminal S * When the stop switch is set to ON, the contact opens. When the S'Nitch :s set to OFF, the contact closes. 7

18745

On normal condition, solenoid 2 is energized and the stop

lever A of the injection pump governor is at the drive side B to keep the engine in running condition. â&#x20AC;˘ When a trouble occurs, current to activate the solenoid is cut off and solenoid 3 loses its pulling force. T hen the stop lever A is pulled to the stop side C by its return spring and the engine is stopped.

18746

54-28

54 Before engine starts

Battery switch 4: ON 5 ➔ 4 ➔ 6 ➔ 7 (B) ➔ 9 ➔ 3 -➔ 1 (B)

As the voltage is applied to terminal B of the solenoid relay 1, but is not applied to terminal S, the solenoid relay is not energized. Therefore, cur rent does not flow to the solenoid relay 2 and solenoid relay 2 does not operate.

When engine starts 1

• Position of starter switch 7: START 5 ➔ 4 --➔ 6 ➔ 7 (B) ➔ 7 (C) ➔ 1 (S) ➔ earth 2

• At this point, internal switch of the solenoid relay 1 turns on and the cur rent flows as follows:

-B--

1 (B)

--r

Internal coil of relay➔ Earth � Internal switch of relay ➔ 1 (C) ➔ 2 ➔ Earth

• Due to the activation of the solenoid 2, the stop lever A of the injection pump governor is pulled to the position B and the engine starts.

5 18748

r]l

A®:j

18}� I

� 18749

54-29

STRU TURE

After engine has started 1

• Position of starter switch 7: ON

The current from the starter switch (terminal C) to the solenoid relay 1 (terminal S) is cut off. However, solenoid 2 remains activated as the internal switch is kept in the ON position by the capacitor in the relay. • During this period, engine oil pressure increases to close the engine oil pressure switch 10, and the current flows as follows:

10 8

7 (BR) ➔ 10 ➔ 11 ➔ 1 (H) ➔ Internal coil of relay➔ Earth

• In this way, internal switch of relay is held ON to keep the engine run ning irrespective of the discontinuation of the current to the terminal S of the solenoid relay 1 .

18750

When engine is automatically stopped When the oil pressure abnormally falls or the coolant temperature abnor mally rises while the engine is running, the contact of the engine oil pres sure switch 10 or coolant temperature sensor (thermo switch) 11 turns OFF to stop the supply of current to the solenoid relay, so the solenoid relay stops operating. Accordingly, the solenoid 2 also stops operating, and the stop lever A of the governor is moved to the stop position by the return spring and the engine is stopped.

5 18751

18752

54-30

54 When engine is manually stopped â&#x20AC;˘ Position of stop switch 3: ON (ON: Contact is opened; OFF: Contact is closed) When the current to the solenoid relay 1 (terminal B) is cut off, the curÂ rent from the solenoid (terminal C) to the solenoid 2 is also lost, and the engine is stopped in the same way as the automatic stop.

3 10 8

54-31

TR UBLESH Alternator Defective conditions .!:a Q.) ct!

I-

Q.)

Remarks

0-0

C: Q.) ·- 0) en ,_ ct! ·I- .c 0 (.) ._ en ·-

ct! C: "O

a5 ..!.

.:!=�

Probable causes

<( 0

Connector incorrectly connected, harness open-circuited, defective grounding Blown fuse Weak tension of V belt

Broken V belt

0 0 0 0

Defective battery Alternator

Stator coil open-circuited Stator coil and core short-circuited

Field coil defective Rectifier defective Regulator defective

Brush worn (if brush is provided) Sagging brush spring (if brush is provided)

Defective wiring

54-32

0 0 0 0 0 0 0 0 0

0 0 0 0 0

rn Gr 14

[O Gr 14

54 Starter Starter starts but engine does not start

Defective condition

��

�

·c

-� Q)

�

t:: ro

0 C

(f) (1)

"'O

t::

Possible causes

co if)

Connector incorrectly connected, harness open-circuited, defective grounding

Blown fuse

(])2 E.-

(.)

0 C

,_ (J) Cd Q) Q) 0 CJ)

"'O CJ)

c-5 0 ,._ ·-.c c-

a:"§:

Contact of magnet switch binding or deposited Coil of magnet switch open-circuited

Q) +-'

CJ)+-'

.ccti

(J) (/) Q) (1)

o -o c.o

(.) :5

·c co ·- Q)

0 ,._

0... CJ)

·a, C

(])

en0

0 C

(J) Q)

cao-t::cu

(f)

+-'

a5o �c ,._ (J)

.c (])

Q) .0 +-'

0 C C

Q) 0

(])

"'O

t:: ro

+-' (J)

+-'

,._ .c

-� Q)

-0 LL "O

t�

w w w

0 0 0

Remarks

·a, ·a, ·a, C

0 0 0

Insufficient capacity of battery Starter

CJ)

(J) Q)

0 0

Overrunning clutch in defective operation Worn or damaged pinion Defective starter relay

Defective starter switch

()

Worn or damaged ring gear of flywheel

0 [I] Gr 11

()

Starter, Preheater Defective condition �

ca t::

enco

,._

Remarks

.B 0 C

,._

�

'�

Possible causes Defective heater relay or glow relay wiring Defective battery wiring Defective air heater or glow plug wiring Defective air heater or glow plug Defective coolant temperature sensor Defective coolant temperature sensor wiring

(.) Q)

·a, ·a,

� w

0 \J 0 0 "-_) 0 r, 0 0 ('

Gr 14

54-33

ENT

NANO

N-VEHICLE INSPE

1. Inspection of Preheater System <Glow Plug Specification> • Set the starter switch to OFF. • Connect the inspection lamp 2 (24V-1.8W or thereabouts) to the glow plug 1. • Set the starter switch to the HEAT position. • If the inspection lamp 2 does not come on, check the glow plug or heater relay.

08718

2. Inspection of Safety Relay Service standards Location

Maintenance item

Unit: mm Standard value

Limit

Output voltage at terminal P

When engine is stationary

1V or less

While engine is running (ai iuie, 600 rpm or more)

Output voltage at terminal R

While engine is running

Approx. 24V

Output voltage at terminal S

When engine is started (in cranking state)

1V or less

Output voltage at terminal L

While engine is running

5V or less (but not OV)

Replace alternator or wiring. Check and replace wiring.

16V

54-34

Remedy

Check and replace wiring. • If the output voltage is close to the battery voltage, replace the safety relay. • If the output voltage is OV, check and replace parts • Replace • If the output voltage is close to the battery voltage, inspect the alternator and herness and replace if neeessary.

54 (1) Checking output voltage at terminal P • Connect the voltmeter (pointer type) 7 as shown.

1 Battery 2 Battery relay 3 Starter switch 4 Fuse 5 Alternator 6 Safety relay 7 Voltmeter (pointer type) 4�-----

18469

l 5 p E

p 17534

A: To terminal B of starter relay D: To terminal L of starter relay E: Terminal E L: Terminal L P: Terminal P R: Terminal R S: Terminal S .. Measure the vc!tage between termin2! P ,n !he illustration and the ground. • If the reading is out of the standard va!ue, the alternator 5 or wiring is defective. Check all the parts and replace defective ones. • Start the engine and let it run at idle (600 rpm or more) and measure the voltage. • If the reading is 0V, the wiring to terminal P is short-cir cuited. Check the wiring and connector connections. Replace if defective.

17535

54-35

N-VEHICLE INSPECTI N AND ADJUST ENT (2) Checking output voltage at terminal R • Connect the voltmeter 7 as shown. • Place the starter switch 3 in the ON position and measure the voitage. • When the reading is out of the standard value, check the wiring. Replace if defective.

18471

p E

s 17534

54-36

17535

54 (3) Checking output voltage at terminal S 3

18470

• Connect the voltmeter 7 and lamp 8 as shown. • Set the starter switch 3 to the START position and mea sure the voltage between the safety relay 6 (terminal S) and the earth in the cranking state. • If the reading is out of the standard value, the following points are likely to be defective. Check all the points and replace if defective. • When the reading is close to the battery voltage, the safety relay 6 is defective. • When the reading is 0V, the following problems are sus pected. Defective wiring Incorrectly connected connector Defective starter relay Defective starter switch • Start the engine and let it run at idle (600 rpm or more). • Measure the voltage at terminal P. • If the read;r.g :s c:..:t cf the standard va!!.!e, rep!ace the alternator 5. • In the idling state, check to ensure that the lamp 8 does not come on. When the voltage at terminal P is normal and the lamp comes on, replace the safety relay 6.

5 p E

s 17534

17535

54-37

N-VEHICLE INSPECTI

DJUST ENT (4) Checking output voltage at terminal l (where no charge lamp is provided)

18472

p E

s 17534

54-38

17535

• Connect the voltmeter 7 as shown. • Place the starter switch 3 at the ON position and measure the voltage. • If the reading is out of the standard value, replace the safety relay 6. If the reading is close to the battery voltage, check the alternator 5 and wiring, and replace if defective.

54 3. Automatic Stop System <Shutdown> 1 Solenoid relay 2 Alternator 3 Solenoid

4 Starter 5 Battery relay 6 Battery

7 8 9 10 11 12

4 11

Starter switch Ammeter Stop switch Fuse box Engine oil pressure switch Water temperature sensor

18737

Measure the voltages at the terminals of the solenoid relay 1. Perform checks as described below and replace defective parts. When starter switch 7 is placed at ON position, solenoid 3 operates.

Measure voltage at terminal A. (24V available?)

Measure voltage at terminal ST.

Yes ---- Alternator 2 defective

----1 24V

---- ___ o_v _ __,

Stop switch 9 defective

Solenoid relay 1 defective

54-39

N-VEHICLE INSPECTI N AND DJUST ENT Even when stop switch 9 is set to ON, engine does not stop. OV ··

Measure voltage at terminal ST.

► j Stop switch 9 defective

24V

I I

Measure voltage at terminal C.

.__ (}_'!_ _____ Solenoid relay 1 defective · 24V -----·--·----- .. Solenoid 3 defective

When oil pressure is abnormally low or coolant temperature abnormally high, engine does not stop.

* Measure while engine is running.

Measure voltage at terminal W. *

Measure voltage at terminal A. (28 to 29V available)*

� 24V

Yes

Measure voltage at terminal C. *

l--�------

Engine oil pressure switch 11 or water temperature sensor 12 defective -, Alternator 2 defective

.. j Solenoid relay 1 defective

24V -

-j Solenoid 3 defective

After engine has stopped, solenoid 3 is not caused to be OFF.

Measure voltage at terminal C.

__!}.'!__.__ Solenoid 3 defective

t 24V

24V -··-- ----··-- I Stop switch 9 defective

Measure voltage at terminal ST. Yes

Measure voltage at terminal A. (24V available?)

·-·-��---► Solenoid relay 1 defective

Yes ---·-·--···------- Alternator 2 defective

54-40

54 While engine is running, solenoid 3 is operated and engine stops.

Measure voltage at terminal C.*

* Measure while engine is running.

ďż˝ ďż˝'!_ - ____ , Solenoid 3 defective

24V Measure voltage at terminal ST.*

24V ----- Stop switch 9 defective

ov Measure voltage at terminal W. *

__ov_ __ , 24V

Solenoid relay 1 defective

Engine oil pressure switch 11 or water temperature sensor 12 defective If in order Oil pressure or coolant temÂ perature abnormal

54-41

DJUST ENT

N-VEHI LEINSPE <Run-On>

1 Solenoid relay 2 Solenoid

1 s

3 Stop switch 4 Battery switch 5 Battery 6 Heater relay 7 Starter switch 8 Alternator 9 Ammeter 10 Oil pressure switch 11 Water temperature sensor

s()N--

5 18745

Measure the voltages at the terminals of the solenoid relay 1. Perform checks as described below and replace defective parts. When the battery switch 4 is set to ON, the solenoid 2 is operated. Or when the starter switch 7 is set to the ON position with the battery switch at ON, the sole noid is operated.

Measure voltage at terminal S.

----.1�---------�

Solenoid relay 1 defective

24V �----------, Starter switch 7 defective or incorrect wiring

54-42

54 Even when starter switch 7 is set to ON position, solenoid 2 does not operate. (Battery switch 4: ON)

Defective ---- -► Battery 5 defective

Check battery. Good Measure voltage at terminal B

-- ov

24V

Place starter switch 7 at START position and measure voltage at terminal S. (18V or more available?)

Battery 5 defective (Capacity insuf ficient when loads are placed)

Yes

I No

Measure voltage at terminal C. (Battery voltage available)

I Solenoid relay 1 defective

Yes .____ ____ __ ____ ., -So_ le _ d_ ef _ _no_ id _ _ e________. _ 2 _ _ec_ tiv 'I

N �- I Stop switch 3 defective

Is there continuity between terminals of stop switch 3?

.. --Yes ---• Incorrect w1nng

When starter switch 7 is returned from START position to ON position, sole noid 2 operates. Place starter switch 7 at START position and measure voltage at terminal S. (18V or more available?)

Yes

>------ -J

Solenoid relay 1 defective

-------��-�►, Battery 5 defective

54-43

ENT

N-VEHI LE INSPE When oil pressure is abnormally low or coolant temperature abnormally high, engine does not stop.

* Measure while engine is running.

24V

Measure voltage at terminal H.* OV

Measure voltage at terminal S. *

Engine oil pressure switch 10 or water temperature sensor 11 defective

24V

Measure voltage at terminal C.*

-- - ____ov_ ____, Even when stop switch 3 is set to OFF, engine does not stop.

Measure voltage at terminal B.

24V

While engine is running, solenoid 2 is operated, and engine stops.

Measure voltage at terminal B. *

Measure voltage at terminal H.*

Solenoid 2 defective

Solenoid relay 1 defective

'------ --ov ___,

Measure voltage at terminal C.*

Starter switch 7 defective

Stop switch 3 defective

Solenoid 2 defective

* Measure while engine is running.

24V

----ďż˝---ďż˝ I Solenoid 2 defective

24V

'------------

Stop switch 3 defective

Solenoid relay 1 defective

Engine oil pressure switch 10 or water temperature sensor 11 defective

If in order

Oil pressure or coolant ternperature abnormal

54-44

54-45

R <24V-35A>

• Removal sequence

1 2 3 4 5

Adjust bolt Adjust shaft <Type B> V beit Alternator assembly CD P.54-48 Adjust plate

* : Alternator bracket WARNING&-------

Before removing the alternator 4, be sure to disconnect the negative 0 terminal of the battery and insulate it with a tape or something else. If the negative termi nal is not disconnected, the battery volt age is always available at terminal B and is dangerous.

®16745

A 1 ......... ;11"11,11 ........ :-- ---· ·---- - 11 h;;HQIIQUVI I ,:n;;\.tUCI l\,C

Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 3. CD Gr 14

®46895

Service standards Location 4

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

Standard value 1500 rpm

20A or more

2500 rpm

29A or more

5000 rpm

33A or more 28.5 ± 0.5V

Limit

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-46

54 ♦ Service procedure [}] Inspection of alternator DC24V

(1) Inspection of performance of alternator

(Inspection by test bench) • Wire the alternator 4 as shown.

NOTE

Each wire must be adequately thick and each connection must be properly secured.

4 F

®167531

A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F : Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 4 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current I 24V-35A I • Measure the current with the alternator 4 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 4. P.54-48 (2) Inspection of performance of regulator

DC24V

®16755

(Inspection by test bench) • Wire the alternator 4 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 4 rotate at a low speed. • Increase the rotating speed of the alternator 4 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-47

R <24V-35

Alternator Assembly

16197

• Disassembly sequence 7 Front bearing

1 Rotor and front bracket assembly 2 Nut

13 Regulator and brush holder

8 Front bracket

9 Stator and rear bracket assembly 10 Stator assembly 11 Cover 12 Brush

Pulley Rear bearing Rotor assembly 6 Cover

NOTE

Do not remove parts 4, 7, 10 and 12 unless they are found to be defective.

• Reassembly sequence 9:

14--> 13--> 12--> 111 , 5 __r 16 ➔ 10 1

54-48

1: I

[O P.54-47

14 Slinger 15 Rectifier 16 Rear bracket

54 Service standards

Unit: mm Maintenance item

Location Rotor assembly

Standard value °

Field coil resistance (at 20 C) Slip ring outside diameter

Brush length

9 to 10.5 n 33 21.5

0 Tightening torques

Limit -

Remedy Replace

32.4 8

Replace Unit: N · m {kgf · m}

♦ Service procedure [}] Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 8 and stator assembly 10. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 9.

CAUTIO If the plain screwdriver A is inserted too far, the coil B of the stator assembly 1 O might be damaged and short-circuited.

16198

16199

[Installation] If the brush 12 is protruding from the regulator & brush holder 13, the rotor assembly 5 cannot be mounted on the rear bracket 16. Therefore, per form the following steps. • Push the brush 12 into the regulator & brush holder 13. • Insert the pin C from the rear of the rear bracket 16 and press the pin C against the pin hole D to hold the brush 12. If the brush 12 is worn and the pin hole D gone, hold the end of the brush 12 with the pin C. • After installation, slowly remove the pin C.

54-49

R <24V-35A> [Disassembly]

CAUTION,&--------------

When the rotor assembly 5 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they wm be broken or damaged.

16223

W Removal of rear bearing CAUTION.&-------------

When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush wm fail to make good con� tact.

16224

[]] Inspection of rotor assembly (1) Resistance of field coil

• Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly 5.

04757

(2) Continuity between slip ring and core • Check to ensure that there is no continuity between slip ring A and core 8. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 5.

04758

(3) Outside diameter of slip ring • If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 5. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION,&------------

Do corrective grinding within the extent that the outside diame ter of the slip ring A does not exceed the limit.

54-50

54 [IQ] Stator assembly

[Removal] • Disconnect the leads A and remove the stator assembly 10 from the rectifier 15. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION.&_------------- De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

167461

[Inspection] (1) Continuity between leads

• Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 10.

®02336

(2) Continuity between each lead and core

• Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 10.

®02337

I ',_1 � .

r�-, -- _ :]

�" !

ffgJ Brush A

[Removal] After removing the cover A, de-solder the leads of the brush 12 and remove the brush from the regulator & brush holder 13.

�

�-12

16225

54-51

R <24V

----13

[Installation] • Install the brush 12 in the regulator & brush holder 13 in the direction shown. • After installation, solder the leads of the brush 12 to the regulator & brush holder 13. Thereafter, fit the cover A as before.

16231

[Inspection] If the length of the brush 12 is near the wear limit B, replace.

B 04786

Removal of regulator & brush holder

• Remove the regulator & brush holder13 by de-soldering the two illus trated points A. • For installation, reverse the order of removal. A

16232

� Inspection of rectifier

.-----E

• Check the rectifier 15 to see if the internal diodes function properly.

A -------ll£,---+--+-------llillllil+-----. C---+-----+---�-----F

A, B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

D -----+--+--.-----w!llll>!----'

'-------G G

Resistance infinite in both cases .... Open Resistance close to f:! in both cases ... Short

®13084

• Exchange the Ef) and 8 sides of the tester and perform checks in both cases.

CAUTION&--------------

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 15, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

54-52

16233

(with brush)>

R <24

• Removal sequence 1 2 3 4

Adjust bolt V-belt Alternator assembly Q_J P.54-56 Adjust plate

* : Alternator bracket

WARNING.&,-------------------------

Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something eise. it the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 2. CiJ Gr 14

Service standards Location 3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

Standard value 1500 rpm

32A or more

2500 rpm

64A or more

5000 rpm

78A or more 28.5 ± o.sv

Limit

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-54

54 ♦ Service procedure

@] Inspection of alternator DC24V + -

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Aiternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard".

Nominal value of alternator current

I 24V-80A I

�Je

DC24V

®16755

• Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. 1 Ll P.54-56 (2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G : Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-55

(with brush)>

R <24 Alternator Assembly

10699

• Disassembly sequence

1 Rotor & front bracket assembly

2 Nut 3 Pulley 4 Fan 5 Spacer 6 Rear bearing 7 Rotor assembly 8 Cover

9 10 11 12 13 14 15

16 Brush spring 17 Regulator & brush holder OJ P.54-55 18 Rectifier 19 Rear bracket

Cover Front bearing Oil seal Front bracket Stator & rear bracket assembly Stator assembly Brush

0 : Non-reusable part

NOTE

Do not remove parts 6, 1 O and 14 unless they are found to be defective.

• Reassembly sequence 13 ➔1

54-56

13: 119➔18➔17➔16➔15➔14

8➔ 6

54 Service standards Location 7

Unit: mm Maintenance item

Rotor assembly

Field coil resistance (at 20 C) Slip ring outside diameter

Brush length

Spring pressure of brush spring

Standard value

Limit

Remedy

7.2n

Replace

40.4

3.1 to 4.3 N {0.32 to 0.44 kgf}

2 N {0.2 kgf}

0 Tightening torques

Replace

Unit: N · m {kgf · m}

♦ Service procedure

OJ Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 12 and stator assembly 14. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 13.

CAUTION&_-------------

lf the plain screwdriver A is inserted too far, the coil B of the stator assembly 14 might be damaged and short-circuited.

1 10700

16199

[Installation] If the brush 15 is protruding from the regulator & brush holder 17, the rotor assembly 7 cannot be mounted on the rear bracket 19. Therefore, per form the following steps. • Push the brush 15 into the regulator & brush holder 17. • Insert the pin C from the rear of the rear bracket 19 and press the pin C against the pin hole D to hold the brush 15. If the brush 15 is worn and the pin hole D gone, hold the end of the brush 15 with the pin C. 1111 After installation, slowly remove the pin C.

54-57

R <24V-80 (with brush)> [Disassembly]

CAUTION,6--------------

When the rotor assembly 7 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs F of the core are held, they will be broken or damaged.

10825

[II Removal of rear bearing CAUTION,&.-------------

When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush will fail to make good con tact.

13530

[I] Inspection of rotor assembly (1) Resistance of field coil • Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly 7.

13531

(2) Continuity between slip ring and core

• Check to ensure that there is no continuity between slip ring A and core 8. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 7.

13532

(3) Outside diameter of slip ring • If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 7. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION

Do corrective grinding within the extent that the outside diame ter of the slip ring A does not exceed the limit.

�533

54-58

54 � Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 14 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Six places)

CAUTION

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

®02366

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 14.

'------

\ ®02336 I

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 14.

®02337

� Brush

[Removal] De-solder the illustrated points A and remove the brush 15 from the regu lator & brush holder 17.

CAUTION&_-------------De-soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time.

02353

54-59

R <24V-80 (with brush)> [Installation] • Install the brush 15 in the regulator & brush holder 17 in the direction

shown.

• Mount the pin C in the hole B of the brush 15 to make sure that the brush does not protrude from the regulator & brush holder 17. • After installation, solder the leads of the brush 15 to the illustrated points A.

CAUTION&------------- Soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time.

• After soldering, remove the pin C.

11021

[Inspection] If the length of the brush 15 is less than the limit, replace. D: Length when new E: Service limit length

02355

� Rectifier [Removal] • Remove the rectifier 18 by de-soldering the illustrated portion A.

CAUTION&------------ De-soldering should be done quickly (in about 5 seconds or less). The diodes wm be damaged if heated for a longer time.

• For installation, reverse the order of removal. 02357

54-60

54 [Inspection] • Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

B C

Resistance infinite in both cases .... Open Resistance close to n in both cases ... Short

B, C, D: Leads of stator coil connected E, G: Heat sink portion G

F: Regulator connected

®13084

•

Exchange the EB and cases.

e sides of the tester and perform checks in both

CAUTION&_

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency wm be stronger. Therefore, it is advisable to use the highest possible range.

®130831

54-61

R <12V

> • Removal sequence 1 Adjust bolt

2 V-belt

3 Alternator assembly 4 Adjust plate

m P.54-64

*: Alternator bracket

16748

WARNING&_------------------------

Before removing the alternator 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something eise. it the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal.

• Adjustment after installation Adjust the tension of the V-belt 2. Cll Gr 14

Service standards Location

Standard value

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads 5A or less)

1500 rpm

26A or more

2500 rpm

45A or more

5000 rpm

53A or more 14.4 ± 0.3V

Limit

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-62

54 ♦ Service procedure

DC12V

[I) Inspection of alternator (1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard".

Nominal value of alternator current i2V-60A

• Measure the current with the alternator 3 at each of the specified speeds. • if the reading is out of the standard value, disassemble and check the alternator 3. P.54-64 V

(2) Inspection of performance of regulator (Inspection by test bench)

DC12V

16750

• Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-63

R <12 Alternator Assembly

16751

• Disassembly sequence 1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan 5 Spacer 6 Spring 7 Rear bearing 8 Rotor assembly 9 Cover

Cover Front bearing Cover Oil seal Front bracket Stator & rear bracket assembly Stator assembly 17 Connector

10 11 12 13 14 15 16

18 Brush 19 Brush spring 20 Regulator & brush holder [O P.54-63 21 Rectifier 22 Rear bracket 0 : Non-reusable part

NOTE

Do not remove parts 7, 11 and 16 unless they are found to be defective.

• Reassembly sequence 15➔1

54-64

15:

13 8

11 9

10 6

54 Service standards Standard value

Maintenance item

Location 8

Unit: mm

Rotor assembly

Field coil resistance (at 20° C) Slip ring outside diameter

Brush length

Spring pressure of brush spring

2.4 n

Limit -

40.8 to 41.2

40.4

Replace

3.1 to 4.3 N {0.32 to 0.44 kgf}

2 N {0.2 kgf}

Replace

0 Tightening torques

Replace

Unit: N · m {kgf · m}

Location 2

Remedy

Remarks Nut

♦ Service procedure

[I] Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 14 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 15.

CAUTION&-------------

11 the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

10700

\ 18 20

16199

[Installation] If the brush 18 is protruding from the regulator & brush holder 20, the rotor assembly 8 cannot be mounted on the rear bracket 22. Therefore, per form the following steps. • Push the brush 18 into the regulator & brush holder 20. • Insert the pin C from the rear of the rear bracket 22 and press the pin C against the pin hole D to hold the brush 18. If the brush 18 is worn and the pin hole D gone, hold the end of the brush 18 with the pin C. • After installation, slowly remove the pin C.

54-65

> [Disassembly]

CAUTION

When the rotor assembly 8 is held in a vice, make sure that the base E of the iugs of the core is held. If the lugs F of the core are held, they wm be broken or damaged.

10825

[I] Removal of rear bearing CAUTION_&--------------

When the bearing puller is installed, use care to prevent damage to the slip ring A. If the slip ring is damaged, the brush wm fail to make good con tact.

13530 I

[1] Inspection of rotor assembly

(1) Resistance of field coil

• Measure the resistance across the slip ring A. • If the reading is out of the standard value, replace the rotor assembly 8.

13531

(2) Continuity between slip ring and core

• Check to ensure that there is no continuity between slip ring A and core B. • If there is continuity, it means a short circuit. Therefore, replace the rotor assembly 8.

13532

(3) Outside diameter of slip ring

• If the outside diameter of the slip ring A is below the limit, replace the rotor assembly 8. • If the outside diameter of the slip ring A is rough or unevenly worn, correct by grinding with emery paper or a lathe.

CAUTION_&------------ Do corrective grinding within the extent that the outside diame ter of the slip ring A does not exceed the limit. �533

54-66

54 � Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 21. The leads are soldered to the diode leads B of the rectifier. (Six places)

CAUTION&------------- 16

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

®02335

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

\ ®023361

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit Replace the stator assembly 16.

®02337

� Brush

[Removal] De-solder the illustrated points A and remove the brush 18 from the regu lator & brush holder 20.

CAUTION&-------------De-soldering should be done quickly (in about 5 seconds or less). The regulator will be damaged if heated for a longer time.

02353

54-67

OA>

R <12 20

A�

[Installation] • Install the brush 18 in the regulator & brush holder 20 in the direction shown. • Mount the pin C in the hole B of the brush 18 to make sure that the brnsh does not protrude from the regulator & brush holder 20. • After installation, solder the leads of the brush 18 to the illustrated points A.

CAUTION&------------- Soldering should be done quickly (in about 5 seconds or less). The regulator wm be damaged if heated for a longer time.

• After soldering, remove the pin C.

11021

[Inspection] If the length of the brush 18 is less than the limit, replace. D : Length when new E: Service limit length

02355

� Inspection of rectifier

�---D

• Check the rectifier 21 to see if the internal diodes function properly, and replace if defective.

A -------<11!1---+--+------illll!Pt----. B ----+---..--�---iill'lillll>!----e-- E C

Resistance infinite in both cases .... Open Resistance close to .n in both cases ... Short

---+---+---9-----RIIIII+---'

._______ F

®13084

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected • Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION&--------------

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 21, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

54-68

54-69

R <24V

OA (with vacuum pump)> • Removal sequence 1 2 3 4 5 6 7

Vacuum pipe Oil return hose Oil inlet hose Adjust plate V-belt Alternator assembly QJ P.54-72 Adjust plate

*: Alternator bracket

16752

WARNING&------------------------Before removing the alternator 6, be sure to disconnect the negative A terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 5. CO Gr 14

Service standards Location 6

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

Standard value 1500 rpm

24A or more

2500 rpm

33A or more

5000 rpm

37A or more 28.5 ± 0.5V

Limit

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-70

54 ♦ Service procedure Inspection of alternator DC24V

(1) Inspection of performance of alternator

(Inspection by test bench)

• Wire the alternator 6 as shown.

NOTE

Each wire must be adequately thick and each connection must be properly secured.

A: Ammeter

B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L

R: Alternator terminal R V: Voltmeter

®167531

• Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 6 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-40A I

• Measure the current with the alternator 6 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 6. P.54-72

(2) Inspection of performance of regulator

(±)

DC24V

(Inspection by test bench)

• Wire the alternator 6 as shown.

A: Ammeter B: Alternator terminal B

C: Switch

E: Alternator terminal E

G: Alternator drive motor L: Alternator terminal L

R: Alternator terminal R V: Voltmeter

®16755

• Set the switch C to ON. • Let the alternator 6 rotate at a low speed. • Increase the rotating speed of the alternator 6 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-71

(with vacuum pump)> Alternator Assembly

180

10114

â&#x20AC;˘ Disassembly sequence 1 Vacuum pump assembly P.54-76 2 O-ring 3 Rotor & front bracket assembly 4 Nut 5 Pulley 6 Fan 7 Spacer

8 Rear bearing 9 Rotor assembly 10 Cover

11 Front bearing 12 Front bracket 13 Stator & rear bracket assembly 14 Stator assembly

NOTE

Do not remove parts 8, 11 and 14 unless they are found to be defective.

â&#x20AC;˘ Reassembly sequence 13:

54-72

19 _, 18

6 =:}, 17-> 15-> 14 1

15 16 17 18 19

Field coil Regulator [O P.54-71 Rectifier Oil seal Rear bracket

0 : Non-reusable part

54 Service standards Location

Maintenance item

Standard value

Field coil resistance (at 20 C)

Approx. 6.2 Q

0 Tightening torques

Limit -

Remedy Replace

Unit: N · m {kgf · m}

♦ Service procedure

[I] Rotor & front bracket assembly [Removal]

CAUTION.&.--------------

Wind a tape around the spline portion A of the shaft of the rotor & front bracket assembly 3 to prevent damage to the oil seal 18 at the time of removal.

• Insert a plain screwdriver A between the front bracket 12 and stator assembly 14. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 3 from the stator & rear bracket assembly 13.

CAUTION.&_-------------

lf the plain screwdriver A is inserted too far, the coil B of the stator assembly 14 might be damaged and short-circuited.

3 10701

54-73

(with vacuum pump)>

R <24V

[Disassembly]

CAUTION&-------------

When the rotor assembly 9 is held in a vice, make sure that the base B of the lugs of the core is held. If the lugs C of the core are held, they wm be broken or damaged.

10819

� Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 14 from the rectifier 17. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION&_-------------

I i4 ®02335

De-soldering should be done quickly (in about 5 secor'!ds O!" �ess). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 14.

®02336

®02337

54-74

54 � Field coil [Removal) • Remove the two screws A.

CAUTION&_-------------

lf the screws Bare removed first, the weight of the field coil 15 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first.

16118

• Remove the three screws B.

CAUTION&-------------

When the screws Bare removed, the field coil 15 wm fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 15.

CAUTION&------------

When the field coil 15 is taken out, the coil lead portion may be caught by the siaior coii. Du,-.'t µuii it out with i.iiidue fvice.

[Inspection] • Measure the resistance between the terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

Inspection of rectifier

• Check the rectifier 17 to see if the internal diodes function properly, and replace if defective.

A B

C F D

®13084

Resistance infinite in both cases .... Open Resistance close ton in both cases ... Short A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected • Exchange the EB and cases.

e sides of the tester and perform checks in both

CAUTION.Lt_-------------

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 17, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

54-75

(with vacuum pump)>

Vacuum Pump Assembly â&#x20AC;˘ Disassembly sequence

1 Vacuum housing 2 O-ring 3 Vane 4 Rotor

5 Plate 6 O-ring

*: Alternator CO P.54-72 0: Non-reusable part â&#x20AC;˘ Reassembly sequence 1

Reverse the order of removal. 00359

Service standards 93

54-76

R <24V

OA (without vacuum pump)> • Removal sequence 1 2 3 4

Adjust bolt V-belt Alternator assembly [1] P.54-80 Adjust plate

* : Alternator bracket

WARNING&------------------------ Before removing the alternator 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 2. [[] Gr 14

Service standards Location 3

Standard value

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

1500 rpm

24A or more

2500 rpm

33A or more

5000 rpm

37A or more 28.5 ± 0.5V

Limit -

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54 ♦ Service procedure

I]] Inspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

®167531

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal A V : Voltmeter • Increase the load resistance F to a maximum (where pract1caliy no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current I 24V-40A j

® 0e

DC24V

• Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.54-80 (2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 3 as shown.

A: Ammeter

®16755

B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V : Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-79

R <24V

OA (without vacuum pump)>

Alternator Assembly <Triple pulley>

17 15

16754

• Disassembly sequence 1 Rotor & front bracket assembly

8 Cover

14 Field coil

2 Nut 3 Pulley 4 Fan 5 Spacer 6 Rear bearing 7 Rotor assembly

9 Front bearing

15 Regulator [[) P.54-79 16 Rectifier 17 Rear bracket

10 Oil seal 11 Front bracket 12 Stator & rear bracket assembly 13 Stator assembly

NOTE Do not remove parts 6, 9 and 13 unless they are found to be defective. • Reassembly sequence

12 ➔1

54-80

12:

17 ➔16 15

:=f-. 14➔13

1: I

0 : Non-reusable part

5 Service standards

0 Tightening torques

Unit: N · m {kgf · m}

Location 2

Nut

♦ Service procedure

OJ Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 13. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12. - • I ..... - ...

\.,AU 11u1-..

A L.Di.-------------------

lf the plain screwdriver A is inserted too far, the coil B of the stator assembiy 13 might be damaged and short-circuited.

09525

[Disassembly]

CAUTION

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

02319

54-81

R <24V

(without vacuum pump)> � Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 13 from the rectifier 16. The leads are soldered to the diode leads B of the rectifier. (Three places)

I 13

CAUTION&_------------- ®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

[Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 13.

®02336

®02337

54-82

54 � Field coil [Removal] • Remove the two screws A.

CAUTION

If the screws Bare removed first, the weight of the field coil 14 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first.

16118

• Remove the three screws B.

CAUTION&--------------

When the screws B are removed, the field coil will fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 14.

CAUTION&-------------

When the field coil is taken out, the coil lead portion may be caught by the �ic:1ior (;uii. Dufi't pu:: it out With ,.iiidt:e force.

[Inspection] • Measure the resistance between terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

02325

5§) Inspection of rectifier • Check the rectifier 16 to see if the internal diodes function properly, and replace if defective.

A B

Resistance infinite in both cases .... Open Resistance close to n in both cases ... Short

C F

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected

®13084

•

Exchange the E9 and 9 sides of the tester and perform checks in both cases.

CAUTION&

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 16, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

®13083

54-83

R <24V-50

> • Removal sequence 1 2 3 4

Adjust bolt V-belt Alternator assembly CI] P.54-86 Adjust plate

* : Alternator bracket *

®46896

\AIADI\Ut..1""' I.:\ l'llfr"U IU'lllU'll""�--------------------------------------

Before removing the alternator 3, be sure to disconnect the negative 8 terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 2. Q] Gr 14

Service standards Location 3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Standard value

Alternator

1500 rpm

24A or more

speed

2500 rpm

38A or more

5000 rpm

45A or more

Regulator regulated voltage (5000 rpm, loads 5A or less)

28.5 ± 0.5V

Limit

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-84

54 ♦ Service procedure

W Inspection of alternator DC24V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

C 3

®167531

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current I 24V-50A I

DC24V + -

®16755

• Measure the current with the alternator 3 at each of the specified speeds. • if the reading is out of the standard value, disassemble and check the alternator 3. P.54-86 (2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-85

R <24V-50 >

Alternator Assembly 6

�

I 12 18

®42355

• Disassembly sequence 1 2 3 4 5 6

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing

7 8 9 10 11 12

Rotor assembly Cover Front bearing Front bracket Stator & rear bracket assembly Screw

NOTE

Do not remove parts 6, 9 and 15 unless they are found to be defective.

• Reassembly sequence 11 ➔ 1

54-86

11:

18 ➔ 17 16

=:}-,

15 ➔ 14 ➔ 13 ➔ 12 I

13 14 15 16 17 18

Screw Field coil Stator assembly Regulator aJ P.54-85 Rectifier Rear bracket

54 Service standards

0 Tightening torques

Unit: N · m {kgf · m}

Location 2

Nut

♦ Service procedure

[I] Rotor & front bracket assembly

[Removal] • Insert a plain screwdriver A between the front bracket 10 and stator assembly 15. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 11. -• I ■-r■-1.1

J'::,,.

\.,1-\U I IVl't �-------------------

If the plain screwdriver A is inserted too far, the coil B of the stator assembly 15 might be damaged and short-circuited.

\.____-..,--,---'

®42356

[Disassembly]

CAUTION

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they wm be broken or damaged.

®42410

54-87

R <24V-50

> Field coil

[Removal] • Remove the two screws 12.

CAUTION

If the screws 13 are removed first, the weight of the field coil 14 will act on the portion connected to the regulator 16 and secured by the screws 12, and damage to the connected portion may result. Therefore, make sure that the screws 13 are removed first.

®19134

• Remove the three screws 13.

CAUTION&_-------------

When the screws 13 are removed, the field coil 14 wm fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 14.

CAUTION

When the field coil 14 is taken out, the portion connected to the rf:yuiatur 16 rnay be caught by ihe stator coii. Don;t puii it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

®16636

[I§] Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 15 from the rectifier 17. The leads are soldered to the diode B of the rectifier. (four places)

CAUTION&_------------ De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

®02335

• For installation, reverse the order of removal.

54-88

[Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 15.

®02336

®023371

[!z] Inspection of rectifier • Check the rectifier 17 to see if the internal diodes function properly, and replace if defective.

Resistance infinite in both cases .... Open Resistance close ton in both cases ... Short

A, B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

D ®15270

• Exchange the EB and cases.

e sides of the tester and perform checks in both

CAUTION&_-------------

®15271

54-89

(brush less)> • Removal sequence 1 2 3 4 5

Adjust bolt Adjust shaft V-belt Alternator assembly [[J P.54-92 Adjust plate

* : Alternator bracket

®468971

WARNING.&------------------------

Before removing the alternator 4, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 3.

Gr 14

Service standards Location 4

Standard value

Maintenance item Alternator Alternator output cur- speed rent (When 27V is generated)

Limit

1500 rpm

56A or more

2500 rpm

86A or more

* When hot 5000 rpm

77A or more

28.5 ± 0.5V

When cold

Regulator regulated voltage (5000 rpm, loads SA or less)

Remedy Check

Replace

�: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-90

54 ♦ Service procedure

(I] Inspection of alternator DC24V + -

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 4 as shown.

NOTE

®167531

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practicaiiy nu load current flows). • Set the switch C and switch D to ON. • Operate the alternator 4 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current

I 24V-80A I

DC24V

®16755

• Measure the current with the alternator 4 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 4. [I] P.54-92 (2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 4 as shown. A: Ammeter B : Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor l: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 4 rotate at a low speed. • Increase the rotating speed of the alternator 4 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-91

R <24V-80 (brushless)> Alternator Assembly � 0 10 11

16756

• Disassembly sequence 1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan 5 Nut 6 Rear bearing 7 Rotor assembly

8 Cover 9 Front bearing 10 Oil seal

11 Front bracket 12 Stator & rear bracket assembly 13 Screw 14 Screw

15 16 17 18 19

Field coil Stator assembly Regulator P.54-91 Rectifier Rear bracket

0: Non-reusable part

NOTE

Do not remove parts 6, 9 and 16 unless they are found to be defective.

• Reassembly sequence 12 ➔ 1

54-92

12:

19 ➔ 18 ::::}-, 16 ➔ 15 ➔ 14 ➔ 13 17

1: I

11➔10➔9➔81,

7➔6 _____r-7 5➔4➔3➔2

54 Service standards Limit

0 Tightening torques

Unit: N · m {kgf · m}

Location

Remarks

Lubricants

Location 10

♦ Service procedure

OJ Rotor & front bracket assembly

□

r ,..,.m...-..,,,-..11 L' l�IIIVYUIJ

• Insert a plain screwdriver A between the front bracket 11 and stator assembly 15. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION_&------------

lf the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and shortmcircuited.

09525

[Disassembly]

CAUTION_&--------------

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

54-93

R <24V-80

(brush less)> � Field coil [Removal] • Remove the two screws 13.

CAUTION&.-------------

lf the screws 14 are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws 13, and damage to the lead portion may result. Therefore, make sure that the screws 13 are removed first.

19140

• Remove the three screws 14.

CAUTION&_------------

When the screws 14 are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 15.

CAUTIONm_-------------

When the field coil 15 is taken out, the coil lead portion may be caugM by ihe siaior coii. Don't puii it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

� Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION,&.------------- 16

®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

54-94

54 [Inspection] (1) Continuity between leads

• Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

®023371

� Inspection of rectifier

�---0

• Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

A---+--+-----+-----1111111111>+----. B---+-_._-+-____111>1-_.-E C ---+---+---4ll'---flilll"t-----' �---F

®13084

Resistance infinite in both cases.... Open Resistance close ton in both cases ... Short A, B, C: Leads of stator coil connected 0, F: Heat sink portion E: Regulator connected • Exchange the ffi and 0 sides of the tester and perform checks in both cases.

CAUTIONLh--------------

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

54-95

R <24V-90A> • Removal sequence 1 2 3 4

Adjust bolt V-belt Aiternator assembiy Adjust plate

P.54-98

* : Alternator bracket A: Connect to terminals L and R. B: Connect to terminal B. C: Connect to terminal C. E: Connect to terminal E.

WARNING&_-------------------------

8efon:: removing ti-,e aiternaiur 3, be :sure io disconnect the negative 8 terminai oi the battery and insuiate it w1tn a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminai B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 2. Q] Gr 14

Service standards Location 3

Maintenance item Alternator Alternator output cur- speed rent (When 27V is generated)

When cold

*When hot

Regulator regulated voltage (5000 rpm, loads SA or less)

Standard value

Limit

1500 rpm

53A or more

2500 rpm

82A or more

5000 rpm

86A or more

28.5 ± 0.5V

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-96

54 ♦ Service procedure

[!] Inspection of alternator DC24V

+ -

(1) Inspection of performance of alternator

(Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

Each wire must be adequately thick and each connection must be properly secured.

A: Ammeter B: Alternator terminal B

C: Switch D: Switch

®167531

E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current 24V-90A

• Measure the current with the alternator 3 at each of the specified speeds. If the reading is out of the standard value, disassemble and check • the alternator 3. P.54-98 (2) Inspection of performance of regulator

DC24V + -

(Inspection by test bench) • Wire the alternator 3 as shown.

A: Ammeter

B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L

R: Alternator terminal R

®16755

V : Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-97

R <24

Alternator Assembly � 0 9 ,

10 11

�

� 14

16756

• Disassembly sequence

1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan

5 Nut 6 Rear bearing 7 Rotor assembly

8 Cover 9 Front bearing 10 Oil seal 11 Front bracket 12 Stator & rear bracket assembly 13 Screw 14 Screw

NOTE Do not remove parts 6, 9 and 16 unless they are found to be defective. • Reassembly sequence

12 ➔ 1

12:

19->18 17

=:}-,

16-> 15-> 14-> 13 I

54-98

15 Field coil 16 Stator assembly 17 Regulator [[J P.54-97 18 Rectifier 19 Rear bracket 0 : Non-reusable part

54 Service standards

0 Tightening torques

Unit: N · m {kgf · m}

Lubricants

♦ Service procedure

OJ Rotor & front bracket assembly

.... _____ ___ .,

Lnt::111vva1J

• Insert a plain screwdriver A between the front bracket 11 and stator assembly 16. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION&-------------

lf the plain screwdriver A is inserted too far, the coil B of the stator assembly 16 might be damaged and short-circuited.

09525

[Disassembly]

CAUTION&--------------

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

02319

54-99

R <24V-90 > � Field coil [Removal] • Remove the two screws 13.

CAUTION&------------

lf the screws 14 are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws 13, and damage to the lead portion may result Therefore, make sure that the screws 13 are removed first.

19140

• Remove the three screws 14.

CAUTION_&-------------

When the screws 14 are removed, the field coil 15 wm fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 15.

CAUTION_&-------------

When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

[!§I Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION_&-------------

®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time.

• For installation, reverse the order of removal.

54-100

54 [Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 16.

®02336

®023371

� Inspection of rectifier E

• Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

Resistance infinite in both cases .... Open Resistance close ton in both cases ... Short

A, B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected

D ®15270

• Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION&-------------

®15271

54-101

ERNAT R <12V

OA> • Removal sequence 1 2 3 4 5

Adjust bolt V-belt Alternator assembly ll] P.54-104 Adjust plate Alternator bracket

WARNING&------------------------ Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

• Installation sequence Reverse the order of removal. • Adjustment after installation Adjust the tension of the V-belt 2. CO Gr 14

Service standards Location 3

Standard value

Maintenance item Alternator output current (* When hot, when 13.SV is generated)

Alternator speed

Regulator regulated voltage (5000 rpm, loads SA or less)

Limit

1500 rpm

38A or more

2500 rpm

65A or more

5000 rpm

76A or more

14.7 ± 0.3V

Remedy Check

Replace

*: "When hot" refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-102

5 ♦ Service procedure

W Inspection of alternator DC12V

(1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

®167531

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F : Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Increase the load resistance F to a maximum (where practically no load current flows). • Set the switch C and switch D to ON. • Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in "Service standard". Nominal value of alternator current 112V-80A I

(±)

DC12V + -

®16755

• Measure the current with the alternator 3 at each of the specified speeds. • If the reading is out of the standard value, disassemble and check the alternator 3. P.54-104 (2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor l: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and mea sure the voltage (regulated voltage). At the same time, check to ensure that the current value is SA or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-103

R <12V

OA>

Alternator Assembly

� 0 9 10 \ \

7 \

16758

• Disassembly sequence 1 2 3 4 5 6 7

Rotor & front bracket assembly Nut Pulley Fan Spacer Rear bearing Rotor assembly

8 9 10 11 12

Cover Front bearing

Oil seal Front bracket Stator & rear bracket assembly 13 Screw 14 Screw

NOTE

Do not remove parts 6, 9 and 16 unless they are found to be defective.

• Reassembly sequence 12 ➔ 1

12:

19 ➔ 18

54-104

Y 16 ➔ 15 ➔ 14 ➔ 13 I

15 Field coil 16 Stator assembly 17 Regulator [IJ P.54-103 18 Rectifier 19 Rear bracket 0 : Non-reusable part

54 Service standards

0 Tightening torques

Unit: N · m {kgf · m}

Location 2 f�

Remarks

Nut

Lubricant

Location to the oil seal

part oil seal

♦ Service procedure

IT] Rotor & front bracket assembly rn��.,�11 L' n:;111vva1J

CAUTION&_-------------

lf the plain screwdriver A is inserted too far, the con B of the stator assembly 16 might be damaged and short-circuited.

09525

[Disassembly]

CAUTIONLh_-------------

When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

02319

54-105

R <12

> � Field coil [Removal] • Remove the two screws 13.

CAUTION&,--------------

20015

• Remove the three screws 14.

CAUTION&,-------------

When the screws 14 are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand.

• Remove the field coil 15.

CAUTION.Lli------------

When the field coil 15 is taken out, the coil lead portion may be caught by ihe stator coii. Don't pull it out with undue force.

[Inspection] • Measure the resistance between terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

[!§I Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 16 from the rectifier 18. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION&,------------ 16

®02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes wm be damaged if heated for a longer time.

• For installation, reverse the order of removal.

54-106

®02336

®023371

� Inspection of rectifier

•

A B

Resistance infinite in both cases .... Open Resistance close to n in both cases...Short

C F

A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected

®13084

•

Check the rectifier 18 to see if the internal diodes function properly, and replace if defective.

Exchange the EB and 8 sides of the tester and perform checks in both cases.

CAUTION&

When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 18, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range.

®13083

54-107

RTER <24V-5k

> • Removal sequence 1 2 3 4

Starter relay P.54-149 Battery cable EB Earth strap Starter assembly P.54-110

B: Terminal B S: Terminal S

WARNING_&-----------

Before removing the starter assembly 4, be sure to dis connect the negative terminal of the battery and insu late it with a tape or something else. If the negative ter minal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous.

• Installation sequence Reverse the order of removal.

16759

54-108

54-109

RTER <24V-5k > Starter Assembly

��/ II

17 20

15 ®47262

• Disassembly sequence 1 Stopper ring 2 Pinion stopper 3 Pinion 4 Spring 5 Magnet switch 6 Shim 7 Rear bracket 8 Packing 9 Yoke & brush holder assembly 10 Brush spring 11 Brush 8 12 Brush holder assembly 13 Yoke assembly 14 Brush EB

54-110

15 16 17 18

19 20 21 22 23 24 25 26

Yoke Armature assembly Rear bearing Armature Ball Front bracket assembly Cover Packing Planetary gear Packing Plate Gearshaft & overrunning clutch assembly E-ring

28 Gearshaft & Internal gear assembly 29 Gearshaft assembly 30 Washer 31 internal gear 32 Overrunning clutch 33 Lever assembly 34 Front bearing 35 Oil seal 36 Front bracket 0: Non-reusable part

54 CAUTION& ------------------------• Do not remove the bearings 17 and 34 unless defects are evident. • When the armature assembly 16 is removed, the ball 19 might come out with it. Take care not to lose the ball. • it is not necessary to remove the pinion 3 when only the motor should be removed and inspected for inspection of the brushes and the related parts. • Be sure to remove the pinion 3 before disassembling any other parts. • Assembly sequence Follow the disassembly sequence in reverse. CAUTION& ------------------------ Whenever the magnetic switch 5 is replaced, the pinion gap must be adjusted. • Inspection after reassembly CI] P.54-112

Unit: mm Maintenance item

Location

10 11, 14

Standard value

Pinion gap No-load characteristics

Limit

Remedy

0.5 to 2.0 During 23V supply

Current

Adjust

85A or less

Check

3300 rpm or more

29 to 39 N {3 to 4 kgf}

20 N {2 kgf}

Replace

Brush length

Replace

Outside diameter of commutator

31.4

Replace

Rotating speed

Spring pressure of brush spring

Commutator outer circumferential runout Depth of mica between segments

0.05 or more 0.2 or less

Repair or replace

pj Lubricant Location 5

Points of application

Specified lubricant

Quantity

Lever contact surface of magnetic switch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Teeth of armature assembly gear

MOLYKOTE ® AG650

As required

Sliding surfaces of armature assembly and gear shaft assembly

MOLYKOTE ® AG650

As required

Ball

MOLYKOTE ® AG650

As required

Teeth of planetary gear and internal gear

MOLYKOTE ® AG650

As required

Sliding surfaces of gear shaft assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

30 32

Washer

MOLYKOTE ® AG650

As required

Splines of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Sliding surfaces of lever assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

16,29

23,31 29,32

54-111

RTER <24V-5k

♦ Service procedure • Inspection after reassembly After reassembly, check the starter by supplying current.

WARNING,&-------------

• When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it.

®14266

CAUTION&--------------

� The time during which current is supplied to the starter should be limited to 1 0 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • When current is supplied to the starter, a large current that exceeds 1 00A will flow. When the starter is inspected, therefore, use thick cables like boostP-r cablf:ls_ Check to e!"!S!..!!'e that a!: the connections are tight and secure. (1) Performance test • Wire the starter as shown.

B 3

A: Ammeter B: Starter terminal B C: Switch

D: DC power supply S: Starter terminal S V: Voltmeter

• Set the voltage at 23V DC.

CAUTION_&------------®10767

The voltage that is applied should be limited to 24V maximum.

CAUTION&------------

®14258

When the switch C is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply Dis supplied from terminal B of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds.

• Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion 3 with a stroboscope. • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-112

54 (2) Pinion gap [Inspection) • Wire the starter as shown. C: Switch

10768

D: Switch E: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch C and switch D to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC24V

®142591

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch D to OFF to stop rotation of the pinion.

DC24V

CAUTION&------------

When the switch C and switch Dare set to ON, current is sup plied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch Eis set to OFF immediately (in less than 5 seconds) after the pinion has started rotating.

®14260

• Pull out the overrunning clutch 32 by hand, then push back its end lightly and measure the amount F the clutch moves in the axial direction (pinion gap). • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, replace the lever assem bly 33.

®10769

54-113

RTER <24V-5k > [I] Pinion [Removal] To remove the pinion 3, it is necessary to supply current to the starter and let the pinion spring out.

WARNING

®14267

• When current is supplied to the starter, the pinion 3 wm spring out and rotate. Be careful not to touch it by hand. • The magnet switch assembly 5 may be very hot after the end of inspection. Be careful when you touch it

CAUTION&-------------

• The time during which current is supplied to the starter should be limited to 1 O seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils wm be overheated and baked. • Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever assembly 33 without supplying current to the starter, the front bracket 36 and lever could be damaged by the impact produced when the stopper ring 1 is removed. • When current is supplied to the starter, a large current that exceeds 1 OOA will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure. • Wire the starter as shown. A: Switch C: Switch D: Cable M : Starter terminal M S: Starter terminal S 10768

DC24V

®14259

54-114

• T he following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. • Set the switch A and switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

54 • Immediately (in less than 5 seconds) after the pinion 3 has started rotating, set the switch C to OFF to stop rotation of the pinion.

DC24V

CAUTION&-------------

A C

®14260

When the switch A and switch Care set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch C is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating.

• Set the pipe-like tool E on the pinion stopper 2. • Lightly strike the tool E with a hammer to remove the stopper ring 1 from the ring groove F of the pinion stopper 2. • Remove the stopper ring 1 and remove the pinion 3. • Set the switch A to OFF to stop supplying current to the starter.

F�

CAUTION&,-------------®10779

[Installation] To install the pinion 3, it is not necessary to supply current to the starter. • Install the pinion stopper 2 and pinion 3 on the overrunning clutch 32 in the direction shown. • Set the stopper ring 1 in the ring groove F of the overrunning clutch 32.

(

'� F

When the power supply to the starter is stopped, the pinion 3 may move in and the stopper ring 1 may fit in the ring groove F of the pinion stopper 2 again. In this case, repeat the operations by supplying current to the starter.

®10781

• Pull the pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2.

®10782

54-115

RTER <24V-5k > [I] Magnet switch [Installation] Install the magnet switch 5 on the lever assembly 33 with terminal Sin the direction shown.

®10771

[Inspection]

(1) Open circuit test on coil • Check to ensure that there is continuity between terminals Sand M. • If there is no continuity, replace the magnet switch 5.

®10773

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 5.

M ®10774

(2) Contact fusion check • Check to ensure that there is no continuity between terminals Band M. • If there is continuity, replace the magnet switch 5.

M ®10775

(3) Contact contacting check • Push the end of the magnet switch 5 in to close the internal contact. In this state, check to ensure that there is continuity between termi nals Band M. • If there is no continuity, replace the magnet switch 5.

M ®10776

54-116

54 W Removal of yoke & brush holder assembly To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14. • Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 10 alongside the brushes.

16 ®16083

• Remove the yoke & brush holder assembly 9 from the front bracket assembly 20.

CAUTION_&.-------------

When the yoke & brush holder assembly 9 is removed, do not tilt it downward. Otherwise, the armature assembly 16 may fall down.

• For installation, reverse the order of removal. 20017

IIQJ Inspection of brush spring • Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown. • If the reading is less than the limit, replace the brush spring 10.

11, 14

02466

[3] � Inspection of brush

(1) Length of brush If the reading is less than the limit, replace the brushes 11 and 14.

CAUT

To replace the brush

e 11, replace the brush holder assembly 12.

(2) Commutator contacting surfaces 02465

If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500). Inspection of brush holder assembly • Check to ensure that there is no continuity between the EB side brush holder and side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 12.

54-117

RTER <24V-5k > � Inspection of yoke assembly

(1) Open circuit test on coil

�/

• Check to ensure that there is continuity between cable A and brush EB 14. • If there is no continuity, it means an open circuit. Replace the brush EB 14 or yoke assembly 13.

®02477

(2) Earth test on coil • Check to ensure that there is no continuity between the yoke assem bly 13 and brush EB 14. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush EB 14 or yoke assembly 13.

CAUTION&_------------

®02478

The coil may be short-circuited to the yoke assembly 13 due to the accumulation of worn-off metal particles from the brushes and/or armature.

� Inspection of armature assembly (1) Short circuit test on coil J6

• Bring the iron piece A close to the armature assembly 16, keeping it in parallel.

B: Armature tester

®02471

• Slowly rotate the armature assembly 16 by hand. • If the iron piece A is attracted or vibrates, it means a short circuit. Replace the armature assembly 16.

(2) Earth test on coil • Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 16.

E ®13329

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 16 within the limit.

(4) Condition of commutator surface

54-118

®13330

• If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator por tion C.

54 (5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 16.

®02474

(6) Depth of mold between segments

Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 16.

��tF

F: Depth of mold • Make repairs by grinding the illustrated portion G.

• If the mold portion is as shown, repair or replace the armature assembly 16. Good

No good

®02476

27 ®16917

� Removal of gear shaft and internal gear assembly Remove the E-rings 27 and then the gear shaft and internal gear assem bly 28 from the overrunning clutch 32. Proceed as follows if the assembly 28 cannot be removed due to interfer ence of the splined section A of gear shaft assembly 29 with internal parts of the overrunning clutch. • Press the gear shaft assembly 29 against the overrunning clutch 32. • Turn the gear shaft assembly 29 approx. 1/8 of a turn to change the position of splined section A.

®16915

54-119

RTER <24V

> � Inspection of overrunning clutch Perform the following checks. If there is anything wrong, replace the over running clutch 32. • Check to ensure that when the shaft A is made to rotate in the direction 8, it rotates smoothly. • Check to ensure that when the shaft A is made to rotate in the direction C, it is locked.

®13328

� Installation of lever assembly Install the lever assembly 33 in the illustrated direction on the overrunning clutch 32.

®10778

� Installation of front bearing

• Before the front bearing 34 is press-fitted, install the oil seal 35. • Press-fit the front bearing 34 in the front bracket 36 with a press, using the pipe-like tool A.

35 ®13325

• Stake the front bracket 36 side.

CAUTIONLt_------------ Avoid staking the previously staked points 8.

C: Staking points (4 places)

®13326

54-120

RTER <24V

> • Removal sequence

1 Starter cable EB 2 Starter relay P.54-149 3 Starter assembly P.54-124

s I

8: Terminal B S: Terminal S

WARNING&----------Before removing the starter assembly 3, be sure to dis� connect the negative 8 terminal of the battery and insu late it with a tape or something else. If the negative 8 ter minal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous. • Installation sequence Reverse the order of removal.

2 16891

54-121

RTER <24V

Starter Assembly 6

\\ \

b� \\ \ \ �

�

\�

�29�

21 19 16892

• Inspection before disassembly P.54-124 • Disassembly sequence 1 2 3 4 5 6 7 8 9 10

Magnet switch Cover Front bracket assembly Center bracket Packing Adjusting washer Stopper ring Pinion stopper Pin Lever

CAUTION&

11 12 13 14 15 16 17 18 19 20

Overrunning clutch Gear bracket Gearshaft bearing Gearshaft Cover Sleeve bearing Front bracket Armature assembly Front bearing Rear bearing

21 22 23 24 25 26 27 28 29 30

Armature Packing Yoke & rear bracket assembly Rear bracket Brush holder assembly Brush spring Brush 8 Brush EB Packing Yoke assembly

• Do not remove the bearings 13, 16, 19 and 20 unless they are found to be defective. • When the yoke & rear bracket assembly 23 is removed from the front bracket assembly 3, be careful not to allow the armature assembly 18 to fall.

54-122

54 • Reassembly sequence Reverse the order of disassembly.

NOTE

When the magnet switch 1 was replaced, be sure to adjust the pinion gap.

• Inspection after reassembly P.54-124

Service standards Maintenance item

Location

26 27,28

Unit: mm Standard value

Limit

Remedy

Thrust gap of gearshaft assembly

0.1 to 0.5

Adjust

Pinion gap

0.5 to 4.0

Adjust

No-load characteristics (During 23.5V supply) Armature assembly

Current

110A or less

Check

3,300 rpm or more

Outside diameter of commutator

43.2

42.6

Replace

Runout of outer circumference of commutator

Oto 0.03

0.1

Replace

Depth of mica between segments

0.4 to 0.6

0.2 or less

Replace

25 to 34 N {2.55 to 3.45 kgf}

18 N {1.8 kgf}

Replace

Rotating speed

Spring pressure of brush spring Brush length

� Lubricant Location

Points of application

Specified lubricant

Apply to lever contacting portion of magnet switch.

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Apply to gear shaft mounting section of center bracket

Multipurpose grease [NLGI No.2 (Li soap)]

As required

6 11

Apply to adjusting washer

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Apply to lever sliding surfaces of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Apply to clutch splined portion of gear shaft

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Apply to internal gear of gearshaft

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Greasing portion at end of front bracket

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Quantity

54-123

RTER <24V

> ♦ Service procedure • Inspection before disassembly Thrust gap of gearshaft 14

[Inspection] • Measure the thrust gap of the gearshaft 14. • If the reading is out of the standard value, adjust by the following proce dures. 20035

[Adjustment] • Remove the center bracket 4 from the front bracket assembly 3. • Adjust by changing the thickness of adjust washer 6. Types of adjust washers: 0.25, 0.5 mm

11958

• Inspection after reassembly

After reassembly of the starter, check the starter by supplying current.

WARNING • When current is supplied to the starter, the pinion C will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 1 may become very hot during inspection. Be careful when you touch it.

20036

20037

54-124

CAUTION • The time during which current is supplied to the starter should be limited to 1 0 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • When current is supplied to the starter, a large current that exceeds 1 00A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure.

54 (1) Performance test

• Wire the starter as shown. A: Ammeter B: Starter terminal B D: Switch E: DC power supply S: Starter terminal S V: Voltmeter

C 20038

• Set the voltage at 23.5V DC.

CAUTION&------------

T he voltage that is applied should be limited to 24V maximum.

• The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations ranging from measuring the current that flows through the starter to measur ing the rotating speed are completed in less than 30 seconds. • Set the switch D to ON to supply current to the starter. At the time, the pinion C will spring out and rotate. I" AIITlt"'\t..l J.\ vl-\UIIVn� When the switch D is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply E is supplied from terminal B of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. • Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion C with a stro boscope. • Set the switch D to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-125

RTER <24V

> (2) Pinion gap

20040

[Inspection] • Wire the starter as shown. D: Switch E: 24V DC F: Switch G: Connector M: Starter terminal M S: Starter terminal S • T he following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch D and switch F to ON to supply current to the starter. At the time, the pinion C will spring out and rotate.

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch F to OFF stop rotation of the pinion.

CAUTION

When the switch D and switch F are set to ON, current is sup plied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion C. To prevent baking the pull-in coil, therefore, it is necessary that the switch is set to OFF immediately (in less than 5 seconds).

20042

• Lightly push the end of the pinion C in and measure the amount J the clutch moves in the axial direction (pinion gap).

NOTE

12413

When the pinion is strongly pushed, the pinion moves back, while compressing the spring. • Set the switch D to OFF to stop supplying current to the starter. • If the reading is out of the standard value, it means that the starter has been incorrectly reassembled. Therefore, repeat disassembly and reassembly.

IT] Magnet switch [Installation] Install the magnet switch 1 in the illustrated direction on the lever 10. S: Terminal S

12414

54-126

54 [Inspection] (1) Open circuit test on coil • Check to ensure that there is continuity between terminals S and M. • If there is no continuity, replace the magnet switch 1.

11960

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 1.

11961

(2) Contact fusion check • Check to ensure that there is no continuity between terminals Band M. • If there is continuity, replace the magnet switch 1.

11962

(3) Contact contacting check B

• Strongly push the end of the magnet switch 1 in to close the internal contact. In this state, check to ensure that there is continuity between terminals Band M. • If there is no continuity, replace the magnet switch 1.

11963

[!QI

Installation of lever

Install the lever 10 in the illustrated direction on the overrunning clutch 11.

20043

54-127

RTER <24V

> [DJ Overrunning clutch [Removal] • Set the pipe-like tool A on the pinion stopper 8. • Lightly strike the tool A with a hammer to remove the pinion stopper 8 from the stopper ring 7. • Remove the stopper ring 7 from the gearshaft 14 and withdraw the pin ion stopper 8. 11965

[Inspection] • Check to ensure that the pinion B of the overrunning clutch 11 rotates in the direction C and does not rotate in the direction D. • If there is anything wrong, replace the overrunning clutch 11.

,.,.

11966

[Installation] • Install the pinion stopper 8 in the illustrated direction on the gearshaft 14.

iml ____ 8 � ----14

12416

• Install the stopper ring 7 in the ring groove E of the gearshaft 14. 7 E

12417

• Strongly pull the pinion gear F to securely mount the pinion stopper 8 in the stopper ring 8.

12418

54-128

54 � Inspection of armature assembly (1) Short circuit test on coil • Bring the iron piece B close to the armature assembly 18, keeping it in parallel. A: Armature tester

®02471

• Slowly rotate the armature assembly 18 by hand. • If the iron piece B is attracted or vibrates, it means a short circuit Replace the armature assembly 18. (2) Earth test on coil • Check to ensure that there is no continuity between the commutator C and core D ( or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 18.

02472

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 18 within the limit. (4) Roughness of commutator surface

02473

• If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator por tion C. (5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 18.

®02474

(6) Depth of mold between segments Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 18. F: Depth of mold • Make repairs by grinding the illustrated portion G. ®16078

54-129

RTER <24V

> • If the mold portion is as shown, repair or replace the armature assembly 18. No good

Good

®02476

� Inspection of brush holder assembly 25

• After thoroughly cleaning the brush holder assembly, check to ensure that there is no continuity between the EB side brush holder and side holder plate. • If there is continuity, it means a short circuit Replace the brush holder assembly 25.

� Inspection of brush spring • Use new brushes 27 and 28 and measure the load at the moment the brush spring 26 leaves the brushes as shown. • If the reading is below the limit, replace the brush spring 26. //

27,28

14833

� � Inspection of brush (1) Length of brush If the reading is less than the limit, replace the brushes 27 and 28. A: Brush length

CAUTION&------------ To replace the brush

14832

e 27, replace the brush holder assembly 25.

(2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500).

54-130

54 @QI

Inspection of yoke assembly

(1) Open circuit test on coil • Check to ensure that there is continuity between connector A and brush EB 28. • If there is no continuity, it means an open circuit. Replace the yoke assembly 30.

/ 30

®02477

(2) Earth test on coil

• Check to ensure that there is no continuity between the yoke assem bly 30 and brush EB 28. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush EB 28 or yoke assembly 30.

CAUTION&------------

®02478

The coil may be short-circuited to the yoke assembly 30 due to the accumulation of worn-off metal particles from the brushes andior armature.

54-131

RTER <12V-5k > • Removal sequence 1 2 3 4

Starter relay P.54-149 Battery cable EB Earth strap Starter assembly [D P.54-134

B: Terminal B S: Terminal S

WARNING_&-----------

Before removing the starter assembly 4, be sure to dis connect the negative 8 terminal of the battery and insu late it with a tape or something else. If the negative 8 ter minal is not disconnected, the battery voltage is always available at each of terminals B and is dangerous.

• Installation sequence

Reverse the order of removal. ®47209

54-132

54-133

RTER <12V-5k >

Starter Assembly

ÂŽ47182

â&#x20AC;˘ Disassembly sequence

1 Stopper ring

2 Pinion stopper

3 4 5 6

7 8

11 12 13 14

Pinion Spring Magnet switch Shim Rear bracket Packing Yoke & brush holder assembly Brush spring Brush 8 Brush holder assembly Yoke assembly Brush EB

54-134

15 Yoke 16 Armature assembly 17 Rear bearing 18 Armature

19 20 21 22 23 24 25 26

Ball Front bracket assembly Cover Packing Planetary gear Packing Plate Gearshaft & overrunning clutch assembly

27 E-ring

28 Gearshaft & Internal gear

29 30 31 32

34 35

assembly Gear shaft assembly Washer Internal gear Overrunning clutch Lever assembly Front bearing Oil seal Front bracket Non-reusable parts

54 CAUTION,&--------------------------

• Do not remove the bearings 17 and 34 unless defects are evident. • When the armature assembly 16 is removed, the ball 19 might come out with it. Take care not to lose the ball. • It is not necessary to remove the pinion 3 when only the motor should be removed and inspected for inspection of the brushes and the related parts. • Be sure to remove the pinion 3 before disassembling any other parts. • Assembly sequence Follow the disassembly sequence in reverse.

CAUTION,&------------------------Whenever the magnetic switch 5 is replaced, the pinion gap must be adjusted.

• Inspection after reassembly P.54-136

Service standards Location

10 11, 14 16

Unit: mm Standard value

Maintenance item

0.5 to 2.0

Pinion gap

Adjust

Check

29 to 39 N {3 to 4 kgf}

20 N {2 kgf}

Replace

Brush length

Replace

Outside diameter of commutator

31.4

Replace

No-load characteristics

During 11V supply

230A or less

Current

3400 rpm or more

Rotating speed

Spring pressure of brush spring

Commutator outer circumferential runout Depth of mica between segments

f�

Remedy

Limit

0.05 or more 0.2 or less

0.5

Repair or replace

Lubricant

Location 5

Points of application

Specified lubricant

Quantity

Lever contact surface of magnetic switch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Teeth of armature assembly gear

MOL.YKOTE ® AG650

As required

Sliding surfaces of armature assembly and gear shaft assembly

MOLYKOTE ® AG650

As required

Ball

MOLYKOTE ® AG650

As required

23,31

Teeth of planetary gear and internal gear

MOLYKOTE ® AG650

As required

29,32

Sliding surfaces of gear shaft assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Washer

MOLYKOTE ® AG650

As required

Splines of overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

Sliding surfaces of lever assembly and overrunning clutch

Multipurpose grease [NLGI No.2 (Li soap)]

As required

16 16,29 19

54-135

RTER <12

--\--r-

> ♦ Service procedure • Inspection after reassembly After reassembly, check the starter by supplying current.

-g __

- rV "'

____ 1,, \

WARNING&_ ------------3

®39615

CAUTION&_--------------

(1) Performance test • Wire the starter as shown. A:Ammeter B: Starter terminal B C: Switch

D: DC power supply S: Starter terminal S V: Voltmeter

• Set the voltage at 11 V DC.

CAUTION&_------------ ®26379

The voltage that is applied should be limited to 12V maximum.

CAUTION&------------

®14258

54-136

54 (2) Pinion gap M

[Inspection] • Wire the starter as shown. C: Switch

E: Switch F: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch C and switch E to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC 12V

®14259

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch E to OFF to stop rotation of the pinion.

DC 12V

CAUTION&.------------

®14260

R�

When the switch C and switch E are set to ON, current is sup plied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch Eis set to OFF immediately (in less than 5 seconds) after the pinion has started rotating.

• Pull out the overrunning clutch 32 by hand, then push back its end lightly and measure the amount G the clutch moves in the axial direction (pinion gap). • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, replace the lever assem bly 33.

®28766

54-137

RTER <12V-5k

> @] Pinion

[Removal] To remove the pinion 3, it is necessary to supply current to the starter and let the pinion spring out.

®39618

WARNING_&-------------

• When current is supplied to the starter, the pinion 3 wm spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it.

CAUTION,Lh-------------

®14257

• The time during which current is supplied to the starter should be limited to 1 0 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever assembly 33 without supplying current to the starter, the front bracket 36 and lever could be damaged by the impact produced when the stopper ring 1 is removed. • When current is supplied to the starter, a large current that exceeds 1 00A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure. • Wire the starter as shown. A: Switch C: Switch D: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. • Set the switch A and switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

DC 12V

®14259

54-138

5 • Immediately (in less than 5 seconds) after the pinion 3 has started rotating, set the switch C to OFF to stop rotation of the pinion.

DC 12V

CAUTION&-------------

A C

®14260

CAUTION.&_-------------

(

®10781

• Pull the pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2.

54-139

RTER <12V-5k > [§] Magnet switch [Installation] Install the magnet switch 5 on the lever assembly 33 with terminal Sin the direction shown.

�� 5

33 ®47194

[Inspection] (1) Open circuit test on coil

• Check to ensure that there is continuity between terminals Sand M. • If there is no continuity, replace the magnet switch 5.

®28628

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 5.

M ®28629

(2) Contact fusion check

• Check to ensure that there is no continuity between terminals Band M. • If there is continuity, replace the magnet switch 5.

®28630

(3) Contact contacting check

• Push the end of the magnet switch 5 in to close the internal contact. In this state, check to ensure that there is continuity between termi nals Band M. • If there is no continuity, replace the magnet switch 5.

M ®28631

54-140

54 [fil Removal of yoke & brush holder assembly To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14. • Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 1 O alongside the brushes.

11, 14

®16083

• Remove the yoke & brush holder assembly 9 from the front bracket assembly 20.

CAUTION&------------

When the yoke & brush holder assembly 9 is removed, do not tilt it downward. Otherwise, the armature assembly 16 may fall down.

11 • For installation, reverse the order of removal. ®26390 I

[Qj Inspection of brush spring • Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown. • If the reading is less than the limit, replace the brush spring 10.

10 ®14833

54-141

RTER <12V-5k

[!] � Inspection of brush (1) Length of brush If the reading is less than the limit, replace the brushes 11 and 14. A: Brush length

CAUTION.Lt_------------To replace the brush

®36023

e 11, replace the brush holder assembly 12.

(2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500).

ffgJ

Inspection of brush holder assembly

• Check to ensure that there is no continuity between the EB side brush holder and 0 side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 12.

� Inspection of yoke assembly (1) Open circuit test on coil • Check to ensure that there is continuity between cable A and brush EB 14. • If there is no continuity, it means an open circuit. Replace the brush EB 14 or yoke assembly 13.

®02477

(2) Earth test on coil

• Check to ensure that there is no continuity between the yoke assem bly 13 and brush EB 14. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush EB 14 or yoke assembly 13.

CAUTION.Lt_------------

®02478

T he coil may be short-circuited to the yoke assembly 13 due to the accumulation of wom--off metal particles from the brushes and/or armature.

� Inspection of armature assembly (1) Short circuit test on coil • Bring the iron piece A close to the armature assembly 16, keeping it in parallel. B: Armature tester • Slowly rotate the armature assembly 16 by hand. • If the iron piece A is attracted or vibrates, it means a short circuit. Replace the armature assembly 16. ®02471

54-142

54 (2) Earth test on coil • Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 16.

®13329

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 16 within the limit. (4) Condition of commutator surface

®13330 I

• If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator por iion C. (5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 16.

�--==-�-d

®02474

(6) Depth of mold between segments

Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 16.

F : Depth of mold • Make repairs by grinding the illustrated portion G. ®16078

• If the mold portion is as shown, repair or replace the armature assembly 16. Good

No good

®02476

54-143

RTER <12V-5k

> 28

� Removal of gear shaft and internal gear assembly Remove the E-rings 27 and then the gear shaft and internal gear assem bly 28 from the overrunning clutch 32. Proceed as follows if the assembly 28 cannot be removed due to interfer ence of the splined section A of gear shaft assembly 29 with internal parts of the overrunning clutch 32. • Press the gear shaft assembly 29 against the overrunning clutch 32. • Turn the gear shaft assembly 29 approx. 1 /8 of a turn to change the position of splined section A.

®16917

®16915

� Inspection of overrunning clutch Perform the following checks. If there is anything wrong, replace the over running clutch 32. • Check to ensure that when the shaft A is made to rotate in the direction B, it rotates smoothly. • Check to ensure that when the shaft A is made to rotate in the direction C, it is locked.

®13328

� Installation of lever assembly Install the lever assembly 33 in the illustrated direction on the overrunning clutch 32.

®10778

54-144

I s4 l � Installation of front bearing A

• Before the front bearing 34 is press-fitted, install the oil seal 35. • Press-fit the front bearing 34 in the front bracket 36 with a press, using the pipe-like tool A.

®13325

• Stake the front bracket 36 side.

CAUTIONLt_------------Avoid staking the previously staked points B.

C: Staking points (4 places)

®133261

54-145

PREHE

ER CIRCUIT 1 Starter switch

<24V (air heater) specification> 1

2 Heater relay (or glow relay) 3 Heater indicator (vehicles with air heater) Glow plug indicator (vehicles with glow plugs) 4 Intake air heater 5 Glow plug 6 Battery relay (24V specification) Battery switch (12V specification) 7 Battery

18461

<24V (glow plug) specification> 1

<12V specification> 1

18463

54-146

54 Service standards Resistance of

♦ Service procedure � Inspection of heater relay (or glow relay) (1) Inspection of heater If the fuse A is blown, replace it with one having the same amperage stamped on the fuse.

(2) Inspection of main body

(�f;

• Perform continuity checks according to the following table.

� �

(5) (J)(2)(3'i(4)

When no current is supplied

(c;.,

(4)

(B I earth)

�dy

When current is supplied

0-----0

T here is continuity between terminals. Terminals to which battery voltage is applied: DC24V <24V system> DC12V <12V system>

A: Fuse ®29090

• If there is anything wrong, replace the heater relay (or glow relay) 2.

54-147

PREHE

IRCUIT G] Inspection of intake air heater (1) Inspection of fuse If there is anything wrong, replace the fuse A (127A). A: Fuse (127A) (2) Inspection of main body 18465

Check the terminals for looseness, and the heater element for damage and loose contact with the glass. • If there is anything wrong, replace the intake air heater 4.

[§]

Inspection of glow plug

• Measure the resistance of the glow plug 5 as shown. • If the reading is out of the standard value, replace the glow plug 7. CD Gr 11

( f}

54-148

\ 02513

RTER IRCUIT 1 2 3 4

Alternator Starter relay Starter Battery relay (24V) Battery switch (12V) 5 Battery 6 Starter switch 7 Safety relay

6 18466

Service standards

♦ Service procedure

W Inspection of starter relay • Perform continuity checks according to the following table.

------------------------

-----------

SWEB 2 "'B

When no current is supplied When current is supplied

18017

)

T here is continuity between terminals. (±}-----8 Terminals to which battery voltage is applied DC24V <24V system> DC 12V < 12V system>

• If there is anything wrong, replace the starter relay 2. [2] Inspection of safety relay Measure the resistance value between terminals R-L. If the reading is out of the standard value, replace the safety relay 7.

p E

17530

54-149

P SYSTE

AUT

(SHUTD

18 3

18 19

View A

18737

8 Ammeter 9 Stop switch 10 Fuse box

1 Solenoid relay

2 Alternator 3 Solenoid

14 Rod

15 Swivel joint 16 Ball joint

17 Base lever

11 Engine oil pressure switch

4 Starter 5 Battery relay 6 Battery 7 Starter switch

18819

12 Coolant temperature sensor 13 Lock nut

18 Stop lever

19 Flange bolt

Service standards

Solenoid relay

Solenoid

Delay time at start (after application of 28.5V to terminal 8, and 28.5V to terminal A)

18 ± 5 secs.

Delay time at stop (after application of 24V to terminal 8 and 0V to terminal A)

30 ± 5 secs.

Replace

1.2 ± 0.2

Adjust

Clearance between base lever and case stopper

54-150

Engine oil pressure switch operating pressure Coolant temperature sensor operating temperature

Standard value

0.5A or less

Holding coil current

Remedy

Limit -

Maintenance item

Location

Unit: mm

City water cooling Radiator cooling

78 ± 20 kPa {0.8 ± 0.2 °

gs± 2 c °

101 ± 2 c

kgf/cm2 }

Replace

Replace Replace Replace Replace

54 ♦ Service procedure DJ Solenoid relay i-----""--+--"-d

,-+f()oljlf'-1-fC-----"+---d

Wire as shown at left and perform the following inspections.

w A E 1

.J_

18820

F: Power supply G: Switch H: Solenoid (or coil load: 30 ± 3A) J: Switch K: Switch L: Power supply (1) Inspection of oil pressure timer • Connect 28.5V DC power supplies to F and L. • Set the switch G to ON. • Set the switch K to ON and simultaneously measure the time required before the solenoid H operates. • If the reading is out of the standard value, replace defective parts.

NOTE minutes as the discharge finishing time of the capacitor in the soienoid reiay 1. (2) Inspection of stop timer • Connect 24V DC power supply to F and 28.5V DC power supply to L. • Set the switches G and K to ON. • Set the switch K to OFF 5 seconds after the solenoid H has oper ated. (It takes 5 seconds for the generating voltage of alternator 2 to disappear after the activation of the solenoid.) At the same time, measure the time required before the solenoid returns. • If the reading is out of the standard value, replace defective parts.

NOTE

When the timer is to be re-tested, allow a recovery time of five minutes as the discharge finishing time of the capacitor in the solenoid relay.

(3) Manual stop timer • Connect 24 V DC power supply to F. • Set the switch J to ON to operate the solenoid H. • Measure the time required for the solenoid H to return after setting the switch J to OFF. • If the reading is out of the standard value, replace defective parts.

54-151

P SYSTE

(SHUTD

W Solenoid

[Installation] • Temporarily tighten the ball joint 16 to the rod 14 and thread the other end six to nine times into the swivel joint 15 and secure it with lock nuts 13. • Check to ensure that the rotating portions of the swivel joint 15 and ball joint 16 smoothly rotate. • Mount the solenoid 3 on the engine. • Rotate the bail joint 16 to adjust the length of rod 14, place the stop lever 18 in the normal use position, and install the ball joint with the flange bolt 19.

17 188191

View A

[Adjustment] • Adjust the length of the rod 14 so that the clearance B between the base lever 17 and case stopper A will have the standard value with the solenoid 3 in operation.

C: Solenoid moving direction A

17 ({5l� �

• Firmly tighten the lock nuts 13 at both ends of the rod 14 and stop operation of the solenoid. 18824

CAUTION&_-------------

Do not continue to supply current to the solenoid 3 for more than 20 seconds. Otherwise the solenoid may be burned.

• Switch the switch of the circuit between ON and OFF repeatedly two or three times and check the following items.

CAUTION&_------------ Do not switch the switch rapidly between ON and OFF.

• Check to ensure that the stop lever 18, rod 14 and solenoid 3 move smoothly. • Check to ensure that the clearance B between the base lever 17 and case stopper A have the standard value.

54-152

54 3

[Inspection] Wire as shown at left and perform the following checks.

AUX

NOTE

The checks can be performed by use of either the ammeter C or lampD.

(� (+) 3

18821

A: Power supply B: Switch C: Ammeter • Set the switch B to ON. • If the reading of the ammeter C after activation of solenoid 3 is out of the standard value or the lampD does not light, replace the solenoid.

CAUTION.&_------------

When the check lamp does not light, do not continue to supply current to the solenoid 3 for more than 20 seconds. Otherwise the solenoid may be burned.

188221

[!] Inspection of engine oil pressure switch

A¢ 18825

Perform the following checks. If defective, replace the engine oil pressure switch 11. • Under the condition where no air pressure A is applied to the engine oil pressure switch 11, check to ensure that there is continuity between the terminals (1) and (2). • Slowly apply the air pressure A to the engine oil pressure switch 11, beginning at 0 kPa (0 kgf/cm2 ). When there is no more continuity between the terminals and(�), measure the air pressure and check to ensure that the air pressure has the standard value. B: Air pressure gauge

lg Inspection of coolant temperature sensor

18826

• Put the coolant temperature sensor 12 in a container filled with engine oil. • Before raising the oil temperature, check to ensure that there is no continuity between the terminals and • Slowly raise the oil temperature and stir the engine oil well. • Measure the temperature at the time when there is continuity between the terminals (f:· and • If the reading is out of the standard value, replace defective parts.

NOTE

When the oil temperature is near the operating temperature, slowly heat the oil. (When the operating temperature -S °C is reached, leave it alone for five minutes, and then raise the oil tem perature at a rate of 1 °C in two or three minutes.)

54-153

P SYSTE

DJ s

<RUN- N>

�'

8 �

3 9

View A 18827

"18745

1 2 3 4 5 6

Solenoid relay Solenoid Stop switch Battery switch Battery Heater relay

7 8 9 10 11

Starter switch Alternator Ammeter Engine oil pressure switch Coolant temperature sensor

12 13 14 15 16

Lock nut Rod Ball joint Stop lever Base lever

Service Standards Location

Unit: mm Maintenance item

Solenoid relay delay time

Solenoid

30 ± 4 secs.

Pointer clearance

0.8 to 1.5

Clearance between stop lever and

0.4 to 0.5

Holding coil current

24V system

iA or less

12V system

SA or less

external stopper

54-154

Standard value

Engine oil pressure switch operating pressure Coolant temperature sensor operating temperature

City water cooling Radiator cooling

78 ± 20 kPa {0.8 ± 0.2 °

95 ± 2 c °

101 ± 2 c

kgf/cm2 }

Limit

Remedy Replace Replace Replace

Replace

Replace Replace

54 ♦ Service procedure

OJ Solenoid relay

Wire as shown at left and perform the following checks. F: Power supply G: Switch J: Solenoid (or coil load: 30 ± 3A) K: Switch l: Switch 18828

(1) Inspection of operation of solenoid relay 1 and delay time • Check to ensure that when the switches G and l are set to ON, the solenoid J operates. • Set the switch L to OFF and simultaneously measure the time required before the solenoid J is deactivated. (2) Inspection of relay holding time • Set the switches G and L to ON. After the solenoid J has operated, - --L .J.L - -- - .!.&.-L. V ..,_ r'\fi.. i �ta ll It' �VVll\..,I I J'\. lV Vl'f.

• Set the switch L to OFF and check to ensure that the solenoid J stays in the opemting state for more than 30 seconds. • After checking that the solenoid J is in the operating state, set the switch K to OFF to check that the solenoid is deactivated.

(1J Solenoid 12

12 14

[Installation] • Install the ball joint 14 to the rod 13 and temporary tighten with lock nut

12.

• Check to ensure that the ball joint 14 moves smoothly. • Install the solenoid 2 to the engine. • With the stop lever 15 in the stop position, install the rod 13. Adjust the rod length by turning it.

0 0

View A 14

12 13

i8827

[Adjustment] • Remove the cover of the solenoid 2. • Apply the specified voltage to solenoid 2 and energize the solenoid. • Check that the clearance A between the pointers of the solenoid is within the standard value.

l A

18831

54-155

P SYSTE

<RUN- N>

• With the solenoid 2 kept energized, adjust the clearance C between the base lever 16 and the case stopper B to the standard value by turning the rod 13.

rr::; ffi. 12

D: Solenoid moving direction

18832

• Deenergize the solenoid 2. • Firmly tighten the lock nut 12. • Switch the solenoid 2 between ON and OFF repeatedly two or three times (with approx. 10 seconds of internal) and check the following items.

CAUTION,&------------ Do not switch the solenoid rapidly between ON and OFF.

• Check to ensure that the stop lever 15, rod 13 and solenoid 2 operate smoothly. • Check to ensure that the clearances A and C fall within the standard limits. • Mount the cover of solenoid 2.

1]DDJ�

[Inspection] Wire as shown at left and perform the following checks. A: Power supply B: Switch C: Ammeter

(+) �---0-2 �1

18829

• Set the switch B to ON. • If the reading of the ammeter C after the activation of solenoid 1 is out of the standard value, replace the solenoid. 1

18833

Inspection of engine oil pressure switch

Perform the following checks. If defective, replace the engine oil pressure switch 10. • Under the condition where no air pressure A is applied to the engine oil pressure switch 10, check to ensure that there is no continuity between the terminals and (g)_ • Slowly apply the air pressure A to the engine oil pressure switch 10, beginning at O kPa (0 kgf/cm2). When there is continuity between the terminals CD and CV, measure the air pressure and check to ensure that the air pressure has the standard value. B: Air pressure gauge

54-156

fill inspection of coolant temperature sensor

• Put the coolant temperature sensor in a container filled with engine oil. • Before raising the oil temperature, check to ensure that there is conti nuity between the terminals 1 1_ and (2;. • Slowly raise the oil temperature and stir the engine oil well. • Measure the temperature at the time when there is no more continuity between the terminals (ti and (2). • If the reading is out of the standard value, replace defective parts. 18826

NOTE

When the oil temperature is near the operating temperature, slowly heat the oil. (When the operating temperature -5 °C is reached, leave it alone for five minutes, and then raise the oil tem perature at a rate of 1 °C in two or three minutes.)

54-157

Mitsubishi Engine Parts contact: email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ine

(for industrial use)

J.. MITSUBISHI

ORS COR

R ION SEPTEMBER 2001

566

200 (H)